OK so I've begun designing the outside casing, and there's an issuethe radial bends in the main shell, the 27mm ones that link front>top>back>bottom, you can't flange the edge of them. essentially you can't flange a radial wall around a full-round corner, if you understand what I mean
The only way would be to turn the radial edges, into chamfers. Which in all honestly wouldn't look too bad, you'd just chamfer the other round cut features like the fan holes etc and it would look right as rain.
Also, Looking at all the parts in the case, it needs some re-enforcing to stop it from skewing backwards and forwards. the U-shaped centre section doesnt help it, the only thing that does as a permanent fixture is the sheet metal peice that the motherboard tray latches into (previous posts) but it needs something on the other side.
***EDIT***
Tried it out with a chamfer of 45deg, 3mm rad joins, still a little bit gappy.
There's no easy way around this.
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