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[Xion X2]

The piece that you fab'd there, is that to enclose the PSU? have you decided how you'll vent the hot air?

Sorry, Weevil. I forgot to answer the last part of your question.

I've decided at this point to drill venting holes into the bottom of the front panel to vent the PSU. However, the front panel design is still in progress, so I'm not entirely sure how that's going to look just yet.

Looking good there mate.

One thing I could/should of let you know was. Steel/Ali will stretch in lenght by the thickness of the sheet being pressed. E.G A 2mm sheet will gain 2mm in each direction of a bend on the opposite side/outside of the bend.

If you would like a C channel shape that is 100mm x 100mm x 100mm measuring the outside.
You will need to cut and bend like this 98mm x 96mm x 98mm.

You will have probably worked this out by now.
Sorry for the late info.

Keep up the good work.

Thanks, kg! I definitely appreciate the advice. It did prove to be a little tricky when trying to get the measurements right for the bending.

That seems to work the opposite way that I thought it would. My initial impression was that you would actually lose distance in bending due to the curve, but you're saying that you actually gain distance at that rate? That's very interesting and great to know for future applications.

Luckily, I don't think that slight impact will affect the finished cover because I won't be drilling the mounts until after it's cut and bent, but I'll certainly keep it under consideration.

On a side note, anyone see the new downtown structure that just went up?