Good idea, not made one out of metal yet
The last lot of plastic off cuts that I obtained was working where they were doing a shop refit, perfect for housings 2-3mm thick , still had the protective covering on the cuts, they since told me that i can have the next lot if its local, so its been in the right place at the right time.
When cutting keep the filings so later you can mix with glue, make a past to fill in little gaps, after light sanding round the joins its a nice job, plus you get the buz because the final project is all self build and a one off.
Couple of examples the Minipulse3 and the TGSL, unpainted, TGSL a bit tattly now because of hard use.
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satdaveuk