I got a PM requesting a how to on building the case, so here's a basic walk-through.
Originally Posted by kilimats
Well, I don't know of any DIY guides out there, because to my knowlege, I'm the first person to do it like this. It may not be the first time it's been done, but it was an original idea to me. This is how I did it:
I just used a heat gun to heat it enough to bend it. I clamped it to a flat surface with a sharp corner (a 1"x4") , to bend the corners. You only need to hold it in position for a few seconds before it hardens back up.
To start, cut a sheet that is as long and wide as you want your case, plus the height you want, times two (one for each side).
For example, If you want an 8x10 box that is 4" high, you need a sheet that is 16x18". 8"x10", then 4" height, (times two) means you add 8" to each of your original measurements. (8+8 by 10+8 = 16" by 18").
Cut a a square out of the corners the size of the height you want, in this case, 4" squares out of each corner. Then clamp it on the line you want to bend minus the radius of the bend (or about the thickness of the plexiglass) by "behind" this means you want it on the inside of the box (the flat part, not the sides).
Once your corners are cut out, clamp it to your bending surface. Then heat it slowly and evenly with a heat gun while applying light pressure so you can gauge the flexability of the plexi. When you feel it start to flex, support it so that it doesn't warp and, continue to apply heat for several seconds until it is VERY flexible. If you don't wait long enough, you may crack the plexi glass (like I did in one corner). If that happens, you can weld it back up later, but it won't be pretty.
Then just bend it over the corner of your surface. And use something else flat (I used another board) to press it down and make a good solid bend. You need to keep pressure on it for about 30 seconds while it cools, because it will try to return to its original state (flat).
The first two sides are easy. For the second two, you will need your bending surface to be the same length so that it will fit inside the box you are bending. Use a T-square to make sure the angles are right. This can be tricky, so get creative with your clamping, etc.
After you bend the first two sides, use a soldering iron to melt the corners together in a "tack weld" to keep it in the right position while it cools. You may need to re-heat it a few times to get everything right... Anyway, once all the bending is done, use the soldering iron to weld the corners together completely. You may need to add a small amount of material to get a good solid weld. You can use small scraps of plexi glass as "welding rod".
If you accidentally crack anything, just use the soldering iron and a bit of "welding rod" to "weld" it back.
I used the same method to bend a couple of brackets in a right angle. Then drill a hole in each bracket. Use the soldering iron to fuse the brackets to the box, and you're good to go. A good way to weld two surfaces together is to just slowly push the soldering iron all the way through both surfaces. It makes a sort of "plug weld".
For the bottom of the case, I just cut a sheet of plexi glass to size. I then took two strips of plexi glass the length of the HDD, and half the height I wanted the HDD to be mounted at. I bent them lengthwise and drilled holes that matched the mounting screws on the HDD. I then mounted these new brackets to an old HDD (incase I damaged it with the soldering iron), and placed it where I wanted the harddrive mounted. I took the soldering iron and used the "plug weld" method to attach them to the bottom sheet. Then I went around the edges of the brackets to make sure they were fused to the bottom sheet very well.
That's about it. Hope this helps.