BSE_01

Link

The sheet metal cases were designed in onshape and created using the sheet metal tool that exports a nice flat pattern in dxf. 

I ordered them through Sendcutsend which also offers bending for an extra price (turns out its per part).

Next I ordered the laser cut parts from Ponoko.

After about a week, they were delivered.

I then drilled all the countersinks for the flathead m4's that are used on 90% of the design.

After countersinks it was test fitting the acrylic from Ponoko.

Next they got painted semi-gloss black (in hindsight, I would paint them matte).

Having a semi functional diode laser comes in handy.  The faceplates were cutout, out of order btw the acrylic has already been ordered.  Then I ran the sheet metal flat patterns.

"Cutting"

Final result

After finishing the cut with an exacto

Text fitting the screen and pi

With keyboard, batteries, hinges, and handle.

Fully closed.

I've got all the components designed and the case top and bottom finished.  The sheet metal is off to sendcutsend for cutting and bending.  If it wasn't so close to the deadline, I would have gotten them powder coated instead of the planned rattle can painting.

Open

Closed

I gathered up my existing parts and with a little help of cad and cardboard, I threw together some prototypes to get a feel for the size.  I ran into possibly extending the width another 25mm or so to get some usb panel mounts on the side of the lower section. 

With the size being around 460 x 200 x 70 [18" x 7.5" x 2.75"], another inch or so is worth getting another port.