Modding category is about as close as I think this concept fits into. Basically I want to create a perfect-fit carry case for an Asus EEE PC (though the method, would work for any laptop I would assume). By that I mean, like in those james bond, or spy type films, where the case is perfectly engineered to fit the equipment in neat slots, and nothing else - but its protected perfectly. My idea is to get a block of polystyrene, and craft it with sandpaper, perhaps a metal wire (hooked up to a battery) or just a knife and lots of hard work. Then cover the lot in either carbon fibre or fibreglass and resin. Latches and Handles can be bought - a hinge might be a problem, though a piano hinge might work. The end result would be a case that is *exactly* the right size, fits the items perfectly, and lets not forget, looks cool. Think of this as the "spycase" project. So.... Couple questions first. Anyone think this is at all possible, or can you already see holes in my plan I cant. Second, where the hell do I get the materials - Styrofoam blocks and carbon fibre mesh arent something your just going to be able to pick up - and I've fallen short finding any styrofoam (havent even attempted looking for carbon fibre mesh yet). ideas?
Get the innards made by your local case specialist (there should be someone nearby who specialises in custom camera briefcases etc.)
if you had a semi decent amount of money to drop you could pick up a similar case to what your thinking that has a foam insert that can be customized to fit what ever you wanted to put in it.
the resin used to bond the carbon fibre will eat the styrofoam, and create one hell of a mess. As far as DIY cases goes, ever think of fibre glass, yes its a little heavier and dosen't look as good as CF, but its alot easier to do! CF requires alot of industrail machinary to produce even the most simple of objects. I would start with a MDF template of the foam to make the fibre glass shell, then once the fibre work is done and finished, glue the pre shaped foam inside the shell. MOst motor stores with stock fibre glass sheets and resin, but i would suggest looking online for bulk orders to save some cash, as motor stores tend to stock patching materials. Note the resin used for fibre glass will also eat styrofoam. You'll need to produce your moulds in wood and seal them. Suggest to google fibre glass tuts.
Custom Case Hi, i had the same problem. I solved this way. I used a cheap aluminum bag (by a diy seller) some open cell foam, pencil and cutter. Maybe it can help. Let me know http://www.flickr.com/photos/30663790@N05/
This is going to sound like a wacky idea but it might work, vacuum seal the eeepc in a vacuum bag, cover it with expanding foam so that the eeepc is suspended in an expandable foam block, carve/shape the block then slice through to cut it in half. You could then use the 2 halves to make a mold for your carbon fiber?
I bet Pelican cases has exactly what you're looking for. http://www.pelican.com/case_category.php?CaseSize=%&New=%
Damn, I was just about to post that Pelicans are seriously durable, and usually come with foam inserts you can customize.
