Metal enclosure

[Rich Grise]

Thanks for all the input. I'm finding myself being tempted to go the route
that all the DVD player/amplifier/VHS recorder manufacturers seem to use -
folded aluminum case comprising 2 pieces, with a plastic front panel that
clips on or screws to the aluminum inside. The screws holding the two peices
of aluminum together are at the sides and the rear, out of the way. The cost
of the plastic front panel will be the deciding factor if I do go this
route. Or I could use a milled piece of solid aluminum...

For a solid aluminum panel, I'd look into stamping instead of machining
or even drilling, if you're talking production quantities. But then
again, if you're talking millions, you could afford to have the panel
injection-molded. ;-)

Cheers!
Rich