I'm sure many of you are, like me, impressed with the enclosures that Pete Juliano has been using with his rigs.   Here's an e-mail that he sent yesterday to Bert.  
Hi Bert,
 
You have a ready source of material right there in Seattle and they will  cut it to size. Check out On-Line Metals. The transceiver project has a 4 x 8  inch base plate I bought from them and the front and back are pieces of single  sided copper PC Board. The support material is 1/2 inch aluminum angle stock  (Home Depot). Interesting use of round aluminum pillars. The front and back are  stabilized using 1/4 inch threaded aluminum spacers that were fitted inside of  small diameter hollow aluminum tube I bought in a hobby shop. A dab of Gorilla  Glue holds the spacers inside the tubing and it forms a rigid support  structure.
 
The subject of mechanical construction is a good one and perhaps Bill would  like to cover that in a future podcast. That said I do have a bench top 3 axis  manual milling machine and a 3 axis CNC milling machine (that one cost me about  $250K). The cost was not in the machine but the cost of sending my youngest son  to WSU where he got an ME degree. He designed and built the machine for  me.
 
Boeing Surplus (now gone) in Kent used to sell aluminum plate by the pound  and a lot of my stock (now all gone) came from there. As a retired Boeing  employee I used to get a discount.
 
73’s
Pete
And here is a slide show illustrating Pete's technique: 
https://onedrive.live.com/?cid=4f1e8c71e0d4f1dc&id=4F1E8C71E0D4F1DC%212607&Bsrc=Photomail&Bpub=SDX.Photos&sff=1&authkey=!ADzJ4SgPn5OzRqk
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http://soldersmoke.com/book.htm
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