So i was wondering if you knew where the cheapest place to get a 1 off steel chassis made? You seem to have contacted numerous contractors to get lots of quotes for this case, i thought maybe you might be able to recommend someone to me.
Here are some pics of what I'm thinking of, it's 12.5" x 12.5", x 3.5". I drew up the case and a basic layout for it in Sketchup. I left the PC components intentionally vague so as to not slow down Sketchup when panning view around. The black parts are a foam duct and thermal barrier. As you can see i had to shave about 2mm off the top of the SFX PSU to get the 120mm fan to fit above it.
The case is very detailed though, and i left out cutouts on purpose. I figure the hardest part is getting the case the right size. I can do all the hole cutouts and internal structural work myself. I wanted to keep it as simple as possible so as to keep cost of production down. I'd only want 1, so i don't have to worry about spending a bunch of time cutting holes for every case like you do.
What do you think? See any potential pitfalls? You've been through this process further than i have, so i figure you would have more insight than I.