Seems like replacement TKL cases are not all that common, so I was interested in how you got all the pieces made - any steps from conception to completion that you might be willing & able to share?
Ron Swanson avatar, very appropriate
Unfortunately I forgot to take pictures during the process. It went something like this
Cut 1x8" wood to the size of the case. I forgot what the dimensions are. something like 14" by 5.5" maybe?
Send it upright through my extended bandsaw 1/8" thick. Do this 3 times.
Sand & make it pretty.
Trace pattern from the old plastic case onto one of the pieces of wood.
Drill holes through all of the places where there will be holes.
Here comes the fun part. Use a slew of dremel bits to carve out by hand each hole precisely. Lol I think I skipped the precisely part.
Cut all of the side pieces from the third slice of wood. I marked how high I thought the top plate should be at the front and back and cut sides accordingly. The left and right side pieces will have a slight angle to them.
Stain everything real pretty.
Slap the bare keyboard in there and get gluing. We used hot glue but I recommend wood glue. Also I guess we should have put some sort of epoxy or something on there to make it stronger/less susceptible to warping.
Wait for pretty keycaps to come in the mail.
Take glamour shots and post them to GH and Reddit.