Making Computer Cases out of Plexiglass?

antis0c asks: "After reading many stories on Slashdot about building custom PC cases, I'm highly interested in building one myself. The only problem - I have absolutely no experience working with PlexiGlass/Acrylic/Lexan, basically any plastic type materials. I'd like to learn the basics, cutting, adhesives, special tools, all the skills required to build a PC case out of this stuff. A quick Google search left nothing really good on it, and I can't even find any books on Amazon on the topic. I hoping some Slashdotters might have some insight on good books on the topic, sites, or perhaps just information."

Don't Do It

[Detritus]

If you don't know how to build a case with proper RF shielding, don't do it. If your computer causes interference to legitimate users of the RF spectrum, you can be ordered not to use it.

How would you like it if every motorist in your neighborhood removed the muffler and pollution controls from their cars, because it looked kewl?

Just a guess

[alex_ant]

Someone's not getting any.

Heat

[Overphiend]

One thing to keep in mind when you have a plastic case it the importance of good airflow. In any computer case there are areas of the machine in which air pockets occur, areas where hot air will just sit around. In a normal metal case these areas are usually in the corners, behind the MB, HD's and such. One side effect of a metal case is that the case itself acts a simple heat sink for these areas dissipating the hot spots a little bit. With the amount of heat today's high-end systems put out these hot spots can stay pretty warm over long periods of time, especially if your anything like me and you machine hasn't been off for more then the time it took to install a video card and some memory in the past year. Now in a metal case these spots are mostly harmless, metal can take the heat, however plastic when exposed to certain levels of heat for long periods of time, depending on the plastic, can start to discolor, or warp. So keep this in mind when you are designing the case. One thing I'm surprised we don't see more of is redirecting the airflow through you case much like an air-conditioning vent directs the airflow through a room. The fan that blows air into you case, on the edges of the fan put fins directing a little bit of the air towards the sides and corners of your case, it doesn't have to be much air, just enough to get it moving.