I got my last hammond box from http://www.partsexpress.com for under $20. But if you just google the product number they should show up. Hammond also has clear abs boxes and all sorts of cool things in a lot of different sizes and materials.

Just a thought - could we add a list of good designing programs, such as eMachine Shop or any other program deemed fit to design cases?

I haven't completed a portable yet, but I have used this methods with other projects.
Either from Home Depot, Ace, or any place that sells sheets of clear plastic, I but a sheet or two of paper sized sheets at whatever thickness I need. Then I dremmel out the shape of whatever I'm making. Then to do the sides, I buy sheets of plastic at a small thickness. (I can;t remember how small) Then you wrap the first strip around the edge. Cut it, and glue it. Rinse and repeat until you have it at a good thickness.

For screws, I just superglue a screw post to one side, and screw it in.

This method works good if you take your time and think about what you're doing. Don't rush or you may as well use a tackle box and scotch tape.

Found a site on building a vacuum forming table with some good pics of what's going on:

http://www.tk560.com/vactable4.html

Check out the bottom of the page too for some good links and info on what type of plastic to get.

Another good one: http://www.studiocreations.com/howto/va ... index.html

the cool engraving plastic method as told by master of portables... what i did was made my case out of engraving plastic by cutting out the front plate and the back with an X-acto knife, then cut out walls with the knife, glued it together, bondoed controls on and sanded it down with 40, 60, 100, 220, 320, 600 grits, really smooth, then painted with krylon fusion paint, then basically installed the guts with hot glue!

My Cheap Vac-Forming Guide.

http://benheck.com/phpBB/viewtopic.php?t=18142

Here's another excellent guide for vacuum forming:

http://www.marvin3m.com/vacuum/index.htm

Do many people here make cases with CNC machines? I've found some for fairly cheap on eBay, and would be willing to buy one to mod stuff.

Also, is it hard to make bends and curves in a case? It seems that most people have very straight designs that are all the same height.

Can you send me a link please? The cheapest CNC machines I can find are $600

Yeah...after looking closer I was finding just parts or broken machines for cheap. :/

I have a standard rapid prototyping machine (3d printer) available to me. It uses a plastic base and feeds it out in a very thin line and works from the bottom up.

What are peoples opinions on this technique being used as housing for a Xbox 360 laptop?

If you are looking for some ideas on how to construct a case for whatever system you like. I found this company on the internet. They have a bunch of videos on YouTube and their products are very reasonably priced. They sell fiberglass, carbon fiber, acrylic and plastic sheets ranging from thin to bullerproof (just in case you want to shoot your creation because it is kicking your ass!) They also have difrent colors. Not only that they will cut it to any dimension you like. And no I'm not a salesman just thought it would be a good step off point for people trying to mod or make their own box. Check out http://www.tapplastics.com. some things you have to consider when using plastic/acrylic is that it will get EXTREAMLY hot without poper cooling and ventilation.