[Rhys] wrote in to share a custom project box he built from scratch using polyester resin. He states that in New Zealand, he tends to have problems finding the perfect project box. They are typically too big or small to get the job done, so he figured he might as well just build his own to spec.
Using Google SketchUp, he designed his ideal project box, then got busy building wooden molds. He scored some free melamine scraps from a local company, which he used to build the base of his molding rig. Once the inner and outer molds were built, he secured them to his base and mixed up some polyester resin.
A few hours later, he pulled apart his molds and smoothed out his project box with some sandpaper. He drilled and tapped screw holes, then prepared to make a lid and base for the box.
He admits that the process is quite involved, but there is something to be said for building yourself an enclosure made specifically for the project it is going to house. If you are looking to do something similar be sure to check out his blog – he offers up some sound resin casting tips, as well as some pitfalls to avoid.