Hello,
I'm considering starting a project, and I was wondering if it's possible to get something that I could pour into a plaster mould and hardens to something similar to plastic.
I don't really have the knowledge or tools to use real plastic.

You would need an inside and outside mold to do that.

All you need to make a square box case is a saw, a drill, and some plastic, not hard.

If you don't feel up to it. why not order a premade case from polycase.com?

you could always make some liquid ABS. Cut up anything that's ABS plastic (most electronic cases e.g. controllers, consoles) into little pieces, put into a glass jar with acetone, and wait for it to dissolve. make sure you stir it once it dissolves.

the more acetone you use, the thinner it will be. If it gets too thin, then leave the lid off to evaporate the acetone or put more plastic in to dissolve. You'd probably want it thicker and coat the inside of the mold a few times in thin layers, letting each layer dry first. You'll get little bubbles in it once its dried, but you can sand those out and fill imperfections with epoxy or bondo or whatever you like.

Take a look at Smooth-Cast series of 2 part urethane plastics.

You mix them together and pour into a mold and a short while later, they emerge as solid plastic parts.

http://www.smooth-on.com/Urethane-Plast ... index.html

that is awesome!

a bit expensive, but awesome

If you actually do have a mold, you could use fiberglass resin. It's available at just about any parts store, relatively inexpensive, and goes a long way. You need a cloth, preferably fleece, to stretch over the mold first.

I've used it for a couple projects so far, and it works fairly well. The fumes are killer though!

Are you PlopperZ from GP32X?

If so, welcome!

Liquid ABS is indeed good stuff, I wish there was a premade solution (Takes a long time to make on your own).

what, so if he's not the same PlopperZ, you're not welcoming him?

No, he is still welcome. If he is a different one, I would not be welcoming him, though.

Yup, I'm the same guy.
Recognize a few names around here.
Don't know if I'll be spending much time here though, simply because I don't really belong. I don't think I'd ever be able to rip apart my precious consoles like you guys do
I've been wanting to make a BeagleBoard based UMPC for a while now (bit of a pipe dream), and have a basic idea of how it'd be done. I had no idea how I'd do the casing though, and here seemed like the best place to go for that sortof thing.
I'm weary of using real plastic because of fumes and I don't have a vacuum table or anything like that, so what RManUF suggested is probably my best bet.

How hard/sturdy does this plastic become? Could it be used for a custom case with mold instead of vac-forming?