Cutting plastic to size. Do yourself a favor and use the metric system to measure sizes, you'll end up with a lot more precise fit.
Write on the panels how they fit in the box and their actual orientation.
Mark the location of individual components on the bottom panel, including where the holes for the screws are.
Place some long pieces of plastic along the side of the bottom panel, so you can easily attach with screws the top part of the box.
Adjust the stop on the router attachment, such that the drill doesn't go deeper than necessary.
Drill the holes using the router attachment, so they end up perfectly vertical. Don't forget to put some scrap plastic or wood under the work piece.
Attach the components with protruding elements that you need to expose to the bottom panel. In this case, I wanted to expose the Ethernet port on the GuruPlug. Mark the location of the Ethernet port on the side panel.
Drill some connected holes inside the square for the Ethernet port, to remove the inside plastic.
Use a file to make the hole square.
Removing the plastic inside the hole for the connector.
Cleaning the hole with the file.
Connector fit with screws attached.
Use an adjustable clamp like this to hold the two panels in place during the gluing operation.
With two such clamps you can hold the two panels for a perfect fit.
The bottom part of the box after gluing. It takes few minutes for the glue to take effect and the plastic pieces to be bound together. Don't force the assembly however, as full strength is achieved in 24 to 48 hours.
The 80mm fan needs a hole to be cut. First mark the edges of the fan.
Then draw the diagonals; the intersection is the center of the circle for the fan.
Adjust the circle cutter attachment for the radius of the circle. Here I set it up for slighly less that 4cm (the fan is 80mm).
If you have an end mill which you cannot drill with, first drill a single hole so you can start the milling from it. Replace the drill bit with the end mill and cut the circle. Adjust the Dremel speed to 7000rpm. Go relatively slowly and stop frequently to give a chance to the Dremel to cool off.
Use a file to clean up the circle.
Finally drill the holes for the screws holding the fan.
Glue the panels.
The box with most components attached to it.
I used some strips of plastic on the top part of the box to prevent it from sliding around.
Here is the setup I used for the photos in this album. I used a 550EX and two 580EX flashes, each attached to a Pocket Wizard FlexTT5. The 5Dmk2 camera had a Pocket Wizard MiniTT1 to trigger the flashes. The camera sat on a tripod close to the door on the right.
