Now when know what the inner and outer dimensions of enclosure are, I can do some metalwork.
Enclosure dimensions: 340 x 230 x 320 mm (WxHxD)
Front panel dimensions 350 x 240 x 4 mm (WxHxD)

Enclosure is fabricated from 20mm L shape aluminium profiles. 30 mm diagonal bracing.

Lazy cutting with reciprocal saw 🙂

Easy to achieve right angle with clamps

Finished sides with bracing. This adding stiffness to the enclosure when lifted by rack handles.

With hammond 7″ rack hande

Bottom sheet 2mm thick aluminium. I was testing circle brushing, this will be brushed from inside in latter stage.

My amateur approach in cutting of rear aluminium panel

Drilling holes for rear panel. High accuracy of assembly is achieved in way, that I first drill holes in first part and attach to counterpart by clamps, then drilled holes in counterpart. You get really nice fit this way.

Assembled and all fits perfectly! getting there

Bottom side of enclosure. Rubber feet, time to take off protective film and drill holes for PCB spacers.

Holes for spacers drilled. All looks nice and shiny.

Adding labels to the switches. Label is print out on laser printer, double side tape on bottom side, transparent tape on front side. This makes very easy to produce durable labels.

Adding wiring to the switches. Twisted pair made with cordless drill. White wire 0.1mm2

Installation of assembly modules inside the case. ready for front fascia and wiring.

Detail of rear panel with switchable and fused IEC socket still with protective film. Brushed finish.

Temporary front fascia with fixed tube assembly, easy to work with.1. I still haven’t received the real deal at this point. 2. It would be shame to ruin an final piece.3.Changes to design are required

Detail of tube assembly.

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