Well, I started building my case last night. It is going to be made of Lexan and some aluminum brackets. I have a few pics, but are not with me. I will post those tonight.
For cutting, I tried using a cutting knife (used to cut Lexan), but that worked like crap. So, I busted out the dremel and used that. It did melt a bit, but the cut was still pretty smooth and straight. I had a few mess ups, since I do not have the steadiest hand, but a few times i got sweet a$$ cuts. I definately was shocked.
So, I cut the bottom piece out and lined up the mobo so I could drill a few holes for mounting posts. Drilled the holes, but then remembered that I did not compensate for the posts in my drawings (DUH!!!), so I had to find the smallest posts I had. Well, found some that would work, so i screwed those in, but when I went to mount the mobo, I did not have any screws that would work. Man what a pain. As I was looking around, I found out that those mounts were not really mounts, they were the screws from the serial/parellel ports (you know the ones on the motherboard that allow you to screw in to tighten the printer cable to the mobo). OOPS!! man things are not going as planned. I had some old motherboards and cards laying around so I used those screws to mount the mobo. (will be clarified more when i post the pics)
After that nightmare, I started working on the sides and back. Well, in an event to make the case as small as possible, I mounted the mobo too close to the one side, so I had to cut straight across and down for the rear panel adapter (boy that does not make much sense, but I cannot think of the right words to use at this point, but pictures will clarify so stay tuned). I am thinking of redoing that and just cutting out the ports in the lexan. I think that would look much better.
That is about it for now. I ordered an external USB case for my slim CDRW/DVD from newegg, the Mapower one. Should be here on Monday, so that is kewl. Also ordered about $100 worth of component items from Jameco , ya know, Molex connectors, LED cables, switches, etc.. My inverter got shipped yesterday, oh and I am waiting on my bi-color LEDs (from LSDiodes.com) to show up, hopefully today so I can finish the switch this weekend. FM Modulator should be here soon too.