This was the final result for the box, all aluminium corners covered in carbon fibre vinyl, both inside and out, all of the bolts with blue printed washers and the door corners clearly marked out with blue 90 degree corner pieces.
My intent was to make the box look nice and carbon fibre always makes boring metal bits stand out. I had a bit of dark grey carbon fibre vinyl left over from my SGI mod, so I decided to use it here.
Each of the corners was removed, wrapped in vinyl and bolted back on. They all looked like this on the outside:
The inside was wrapped with a lighter colour vinyl, mostly because I ran out of the dark stuff. The lighter one still looks pretty good I think.
It was a long and tedious process removing each corner piece, wrapping it, and screwing it back in.
When I was about a third of the way through wrapping the corner pieces, I decided to make blue washers for all the bolts because the bolts were causing the vinyl to twist as the bolt was screwed in. This meant removing all the corners again one by one.
This is how you print lots of washers:
I think it was worth adding the washers, they add a nice contrast.
The door I had was the original piece of acrylic I cut out by hand from one of the side pieces, so it had uneven cuts along the corners, I wanted to cover this up, so I printed these:
...and fitted them to the door using double sided tape:
The box also got some corner pieces:
Together, it looks pretty good...
Another thing that was bothering me was that the cable for the exhaust fan was just dangling, so I printed a guide for it and attached it to the box with double sided tape also.
Finally all together, the box looks quite nice!