I'm relatively new to the keyboard hobby. I only got my first mech (a brown QFR) this year, but I'm no stranger to mechanical keyboards.
I've been thinking about what it would be like to make a custom layouts like 65-68, the more uncommon ones or even attaching a few columns to the left, similar to the layout on the Redscarf. The only problems with this is that finding a case for it is hard. They're not like 60% keyboards that have plenty of after market stuff in ebay.
I though about this for a while. The most common options I see that people use is using a layered acrylic/metal sandwich, or using bent metal and not using any case at all, or even going for a carved wooden case, but I don't like the look these solutions have (except maybe the wooden ones).
Then I recalled my other hobby (it's more of an on off hobby over the years), which is building model kits, and one of the things people do there is make custom parts out of stacked plastic plates where Tamiya plastic solvent is used to fuse cut pieces of plastic which will then be sanded, back filled, sanded again, primed, and then maybe some more sanding (the model kit community is obsessed with sanding to get that perfect surface) and painted into finished parts. I thought that perhaps such a process can apply to keyboard cases.
Obviously, an exacto knife won't cut it for thick plastic, so I'm thinking some rotary action is required.
I'm wondering if the DIY masters and veterans of Geekhack can shed some light into this - feasibility, possible issues and what ever issues may come up. This is usually done with thinner pieces, but I've not seen anyone do this with thicker plates, but I know thicker plastic plates are available. The main issue that concerns me is about structural strength. I don't know if this will hold up well.
