The Extrusion Box 1.0 is complete! I've taken all the lessons learned from previous prototypes and rebuilt the structure using aluminum extrusions. Relative to the threaded rods I had used earlier, aluminum extrusions provide a stronger framework with far more consistency in dimension for building.

With the completion of this prototype I now have something I can lug around when I need more computing power than available from an Apple MacBook Air.

Over the next several days I'll flesh out this project page, update the components list and provide a full list of instructions for building your own Luggable PC.

In the meantime, here is a list to posts explaining specific design elements that went into the project.

1. PSU Layout: The heavy power supply unit anchors the chassis.
2. Motherboard Layout: Trying to pack components tightly around a (very) not compact full-size ATX motherboard.
3. Screen Layout Challenges: The wishlist for my perfect screen layout and why it is hard to satisfy all the requirements.
4. Screen Hinge: The final design that satisfied (almost) all of the wishlist.
5. A Tale of Three Corners: Learning how to build better 3D printed structures with threaded rods. (Made irrelevant by the switch to aluminum extrusions.)
6. Angled Feet: A minor design element with major ergonomics impact.
7. Drive Bay: Finding the best way to package 2 x 2.5" storage drives.