D-I-Y Project Enclosures?

cg asks: "Like many others, I come across a cool hardware project that I feel like getting into from time to time. I can usually find the hardware I need and get things working. My biggest problem is enclosing the final product. I've used everything from cheap RadioShack project enclosures to cardboard boxes. What I want are suggestions on how to build professional quality enclosures for these devices (from remote control size to small PC). I am not worried about it passing FCC standards, but asthetics are important."

Good Home-Made Box

[philj]

here [jrcs.co.uk] ... and you get a free pizza with the case, too! :-)

Re:Just off the top of my head

[CharlieG]

Yeah,
those are pretty much the "Usual Sources". You could always go crazy, and get a sheet metal break, and bend your own, OR, if you want to spend $$$ on a one off, I've found that blocks of Aluminum, milled out to fit, then having a matching Al cover, all anodized look great. One shop I used to work at did this. Your taxpayer dollars at work - Actually it was the cheapest way to get a unit that could withstand the G forces we needed.

One thing to remember, if it's a "Hand Held", you'd better think about shock load. What happens when you drop it on the floor? (You WILL - trust me). "Potting" is good for this

Charlie

Fiberglass - the product cover of champions...

[Kefaa]

Because projects can vary in size and shape, consider the old standby of fiberglass forms. You can build the initial form in cardboard if you wish and then encase it as you see fit.

You are not restricted by the how the form has to be resolved (have you ever tried to form a circular case in metal?). In addition, you can make it as pleasing to look at as you have time to sand and paint.

And like all good things, remember to vent. Heat build up is a bad thing (regardless of most materials)

Altoids tins

[ecloud]

I built a 5V regulated power supply in one last weekend. See it here. [bigfoot.com]

Just off the top of my head

[unitron]

Check places like Allied Electronics, Digi-Key, Mouser, MCM Electronics, All-Electronics, Jameco, Circuit Specialists, MECI, Marlin P. Jones, etc.
Look for brand names such as Bud, Ten-Tec, Hammond.