Building my own micro pc case.

[Lithan]

I'm trying to keep costs down, but I was wondering what material would work best for my project. I was thinking 1/4" Acrylic, but I've not had much luck making strong 90* angle bonds (I use all-purpose 2ton test 2part clear-set epoxy). Anyone have any better idea's for materials?

Also, I have a 2u PSU that works great... but it's loud as hell.
http://www.stayonline.com/power_supplies_2u/8977.asp
Anyone have any idea's to silence it? I was thinking of replacing the intake fan at the back with two intakes along the top.

[Hell-Fire]

What size are the stock fan(s)??

You could switch out the stock fans with 120mm if it fits. Would be much quiter and still pushes good air.