really, in the spirit of DIY, how come nobody does it? my case, whch i made 2 years ago is a 3ft brushed aluminum cube and a cheapy antec motherboard tray. it offers so much more flexibility than a standerd case. If you ask at home depot, they can actually make the frame for you, leaving you with cutting out the holes
And what made ya' wimp out and use a pre-made motherboard tray?
Oh well, it's just a whole lot of work really, much easier to buy something made in mass quantities by hoardes of underpaid offshore labor I suppose.
Getting the motherboard and PSU to sit right isn't too challenging. Making the rear apron for the expansion cards is a bit more challening. And fashioning support for the various storage bits can be quite a bit of effort as well.
And not all of us have regular access to a machine shop!
Your post gives me plenty of interesting ideas, none of which I would be able to pursue really, but I'm thinking of wooden computer cases to emulate the appearance of early 20th century radio receiver consoles. Or even bakelite with some Art Deco touches, for folks who wax nostalgic over that era. A retro case with flickery orange neon bulbs, dim yellowish incandescent backlighting and brass accents would really stand out uniquely in this day of colorful, comical plastic cases and super contemporary brushed aluminum alloys.
Easiest thing would probably be to buy a case, keep the framework and internals, and either bond a facade to the case or toss it entirely and build a new exterior completely.
If someone here builds this, mention my name as your inspiration and email pictures to me!
Additionally this topic has grown a few tangents, one in particular being EMP and RFI. With that, one thing that bothers me greatly about the use of acrylics for case exteriors, is that unless it's treated with some kind of conductive coating (like IBM pioneered with the PS/2 I think), these computers end up generating huge amounts of electrical interference and can disturb reception in nearby radio devices. Consider that today's processor frequencies are very close to the radio frequencies of 802.11g and Bluetooth. Don't assume that just because you don't listen to radio and your TV is on cable, that you're immune. Besides, if your neighbor can no longer watch Desperate Housewives he or she is legally entitled to bug the crap out of you until the situation is rectified.
And here's a few links for the paranoid...
http://www.unitedstatesaction.com/emp-terror.htm
http://en.wikipedia.org/wiki/Mu-metal
http://www.cecer.army.mil/facts/sheets/FL16.html
-Brad