I chose to order the larger aluminum pieces from a local metal shop, because I don't have the tools to bend a 3 mm thick aluminum sheet. With a project that had tolerances this small, I really didn't want to take any chances.
The Motherboard Tray
Here you can see the main steps in the fabrication of the motherboard-tray.
The motherboard-tray has a really simple design. The places for the standoffs were drilled into a sheet of polycarbonate. After that spacers were glued into those holes. When the glue had set, I drilled holes into the spacers and threaded them with a m3 thread.
After waiting for a month, the aluminum-parts were finally delivered. Now I really had to hurry up as I only had little over two weeks left to get this project done for the Assembly07 LAN-party.
So here's what I got from the shop.
They actually screwed up the biggest part. They made it too low by half a centimeter. Luckily it didn't cause any fatal problems to the build. At least the parts were a bit cheaper.
Here's a picture just to show you how much clearance I have.
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