Hello gang,
I have seen a plutonium case for sale, but it is way more than I would like to spend. Anyone ever work on one of these and might be able to point me in the right direction?
http://img530.imageshack.us/img530/5131/bttfi10024kn0.jpg
That's an "Anvil case" - I have a couple of larger ones I use for equipment & tools out in the garage. Check industrial surplus, they often pop up there.
Any shelves or dividers installed are likely slid into channels rivetted into place - the shelves are wood (usually 1/8" ply) and may be slid out; then the rivets drilled, the channels removed (they're aluminum, the rivets usually are as well,) and the holes filled with plastic filler of choice, sanded smooth, and painted.
If you look around at the hardware store, you can also find hardware to build one (rounded corner guards, aluminum angle iron for the edges, strip aluminum for around the cut edges of the lid & opening - if not channel stock - and use whatever hinges are appropriate (I've seen Anvils with either continuous piano hinge or individual hinges.) You can use 1/8" plywood, apply spot-fill putty, and sand for a smooth surface to paint. Rivets are usually used to hold things together, insert from the outside, and I suggest the use of backup washers on the inside. Pop rivets are often used, they're easier.
Foam may be sourced from wherever, most foam will cut most easily using metal tube, heated to a dull red (of whatever metal - you just need it to be hot enough to drop through and take out a plug.)
If you can't find the hardware locally, you can find most (if not all) of it through Parts Express - Anvil cases are often used for audio equipment, and concert gear often needs case repair... Google them.