[Sivan Toledo] needed a enclosure for a unique sized electronic project, not finding what he needed in off the shelf solutions, he went to the next best thing, … Papier Mâché!
Using a mold made out of standard corrugated cardboard, he slowly built up layers made of magazine paper, and ordinary “white glue” diluted with water. After getting near the thickness wanted he switched over to typing / copy type paper for a nice clean outer surface. Ports were made in the usual fashion when dealing with soft or thin material, drill a smaller hole, going back with successively larger holes, and then follow up with an appropriate file, all while taking things slow along the way to prevent unwanted results. Finishing up with layers of paper carefully cut into strips to meet the circumferences / edges, along with the final outer surface to make it all even.
The end result is awesome as it stands, but we cant help but wonder what some sanding and paint would look like on a enclosure made like this, though any way you finish it, the idea comes down to custom enclosures that do not need special tools or materials to complete (on the cheap).