Scott sent in his work on developing cheap laser cut enclosures for your next DIY project. I can attest to using the acetone techniques, but I really like the t-nut slots in clear acrylic. That is something I am going to try out in the future. [Thanks Scott]
Making decent enclosures is troublesome because it's almost impossible to find just the right size box, and hacking out the holes for connectors usually takes a lot of time and looks sloppy at best. Designing your own laser-cut, acrylic box takes care of these issues and doesn't even cost that much.
Read more about how to make Laser-Cut Custom Boxes
http://blog.makezine.com/archive/2008/08/how_to_lasercut_custom_bo.html