DIY Project Enclosures

Determine the dimensions for your enclosure. Draw the bottom measurement of the project enclosure on a wood panel with the felt marker. Cut out 4 side walls from the paneling with a circular saw. Place wood glue on the edge of the side walls. Affix walls to the bottom panel on the outside edge of the marker line, creating a box. Remember the felt marker line is the size of the project enclosure that you want. Placing the walls exactly on the marker line or on the inside of the line will create box smaller than your measurements.

Measure the thickness of the walls for the enclosure you're creating. Cut the wood block a size smaller. Place the block into the mold, checking the measurements to ensure the space between the block and the walls of the mold equals the thickness of the project enclosure.

Place a cove bit into the router. Rout out the corners of the wood block. This allows for the making of small triangular inserts for your plastic enclosure box. You will be able to attach a lid to the inserts to secure it on the enclosure box. Affix a piece of wood panel on the top of the block to prevent the liquid plastic resin from oozing over the block and ruining the casting.

Place a piece of board on the bottom of the mold. Put in the wood block. Place shims on the sides of the block so it is exactly center. Cut out two U-shaped supports. Hammer nails into the supports to affix it to the wood block. Take out the wood block, shims and the board at the bottom of the mold. Put the wood block with the supports back on the mold. The supports should hold the wood block up off the bottom of the mold, allowing for the liquid plastic resin to coat the bottom of the mold for your project enclosure.

Create the lid. Take a piece of paneling larger than the box. Measure the size of the lid. Saw along the measurement lines. You should have a cut-out in the wood panel. Attach this to another piece of wood so you can pour the liquid plastic into the cut-out.

Mix the liquid plastic resin in the plastic cups, stirring the chemicals together per the manufacturer's instructions based on the type of liquid resin you bought. Pour the resin into both molds. Push on the block and supports to force the resin to ooze out, distributing the liquid on all sides and forcing air bubbles out. Place a piece of wood panel over the lid mold so the liquid oozes out to create a level surface. Add weight to the lid so the panel doesn't slide. Let the liquid plastic resin cure according to specifications.

Take off the molds from the lid and the enclosure. Trim off excess of plastic with the utility knife from the enclosure and lid. Apply more liquid plastic if you notice pockmarks from air bubbles. Allow the box to fully cure overnight. Drill holes into the corner of the lid and the enclosure insets. Lay your project inside the enclosure. Place in screws to affix the lid to the box.