parts needed:

• sheet of plexyglass - can be found in any home-improvement-shop, look in the garden-part
• very sharp knife
• resin - can be found in home-improvement-shops, if you can't find it look in the car-department

procedure:

A warning ahead: be very exact. You can bend plexy-glass quite a bit so getting it all "curved" happens easyly.

I have made good exoeriences with first using a CAD-program (gives you nice plans to publish with the pictures of your wearable as a bonus), then making an outher case of 2 interlocking parts with no sides, then ataching the sides and in the end add dividers on the inside (maybe even a honeycomb-structure :) ) to make everything as rugged as possible.

I used screws, bolds and mainboard-spacers (come in different diameter and length). Plastic-screws work better for me as they are as hard but lighter and can be cut down. They respond better to being glued in place (using hot-glue for prototyping and later resin for final fixation).

You should make the holes for the connectors after putting the electronics/... in there. That way you cannot possibly get the position wrong. A Drill is a good tool for that, a knife isn't. Drill very slowly, don't heat up the material with the drill or you'll end up with a mess. Try to use a metal-ruler or something else as a guard if you get easily taken away from your path by the drill (it has a momentum after all).

Don't just bend edges, cut them a little bit on the later inside and then bend. Else you'll not get it exact. For 90°-edges you'll have to secure them with resin later. Else they'll rip easily later.

Don't try to bend parts that don't fit into position. If they don't fit make them fit or do it again. It will not hold long being under constand stress, not look good.

-- MarcusWolschon - 13 Apr 2002