UPDATE (AUG 2013):
Finished cases are currently available for order in limited quantities at loneindustries.com.
Like some of you, for a long time I've had this idea (probably silly to many) of building my ideal
mini-itx case. I finally went ahead and had a prototype built. I realize it's probably not everyones style. I added more vents to the prototype than probably needed, so I could test various configurations out. Despite the 1mm aluminum used in the prototype, my setup is very quiet (thanks to Noctua). I think the screw-on side panels help make the case very rigid when assembled. However, something thicker than 1mm might be nicer. There's a long list of minor changes I am going to make to the design. I've also since painted it black, and should have pics next week.
I'd be interested in any thoughts from silentpcreview readers! The case is a little taller than absolutely necessary so that I can clear the PicoPSU wires (on motherboards with side 24pin connector). With a second 80mm fan in place the PicoPSU wires come very close to the fan blades (see post below). Using 80x15mm fans would really help with clearance.
If there is some others with weird taste like me, I can make this available for purchase. Since these are made on CNC equipment, I can't really do one-offs. If I had 10 or more people interested, I could probably have a run of them made, and finished in powder coat of anodized.
Anyway, I never thought making a box could be so involved!
Intel Core i3 3225
Cooler Master 80mm PWM fan (with Noctua low noise adapter, running at about 1000 RPM - down from 1500 RPM)
PicoPSU 80 (60W power brick)
Simple as possible, PicoPSU powered, small as possible without being too small, and probably other stuff.
Mini-ITX tower (220 x 93 x 220 mm)
1.63mm aluminum (powder coat or anodized finish)
2x 80x25mm exhaust fan mounts
2x 2.5" HDD/SSD bracket (SSD recommeded)
1x Low-profile expansion slot
2x 2.5mm DC input, 1x Mini-DIN input hole for PicoPSU power supplies
70 mm CPU clearance (75 mm max)
16 mm anti-vandal power switch
PEM stainless steel nuts, and standoffs (No rivets)
Black rubber case feet
Availability: July 2013loneindustries.com
Finished case in matte black and white: