Okay, it’s time for some PC-builder stuff (hey, it’s required I do one of these every so often because after all it is PCMech, right?)
When people hear "scratch-built", they think, "Oh, okay, I have to buy a case.."
Stop right there.
A true scratch-built is when you either physically construct the case or retrofit some type of box to hold a standard ATX form factor motherboard. And yes, this involves drilling.
I have to put a disclaimer here: If you are under the age of 18, get a parent’s permission before using a drill. And as always, wear safety goggles when drilling and use a work-safe environment.
Where do you get the specs?
Get the ATX specification document formfactors.org. That document link is a PDF, so it will print out properly. It lists all the measurements, space requirements and so on. You need this so when you start drilling holes you know where they’re supposed to go among other things.
If ATX is a bit too large for the box you’re constructing, there’s also the MicroATX specification.
There are also other factors such as Mini-ITX and a ton of other stuff you can download documentation for. FormFactors.org is a PC builder’s best friend when it comes to getting the spec docs you need.
And yes, full diagrams are included with each document.
What can you use to construct the case?
Anything you wish, including wood – which has been done before. If you were to use wood, I would suggest using some sort of non-flammable material on the interior "walls" such as with this soundproofing kit. You can also put extra "insurance" on the wood you use by pre-treating it with a flame retardant coat of some kind.
And it obviously goes without saying that the case should have plenty of vent openings and fan mounts to keep it running cool and to keep it from catching on fire. 
What about PC retrofitting?
This is where you take an older proprietary computer box, gut it, cut it and drill it so it will house a standard modern motherboard, power supply and so on.
An example of this are old clunky desktop workstations PCs, such as the HP Vectra series from the late 1990s/early 2000s, like this one:
There’s a special place in my heart for these old desktop workstations because in all honesty, they look good – even today. The style has held up over the years.
The problem with these HP boxes is that many (if not all) of them have proprietary non-standard motherboards and PSUs in them. When you gut the box, you truly have to gut it completely so there’s nothing left on the inside.
Once you gut it out, the retrofitting process is fairly straightforward. There’s plenty of room for a MicroATX board and a low-power PSU (they’re smaller and will fit easier). You can install 1U-sized server-style fans to keep it cool if need be.
For USB ports, simply route a USB hub from the ports on the back of the new motherboard you install.
As for the floppy drive cover, you could replace with a 13-in-one card reader, but that may prove to be too much of a challenge. The mount that holds the floppy drive is proprietary, and the cover won’t be easy to cut.
The optical drive does have proprietary mounts, but, it is a standard-sized optical drive. That part is easy.
Ready to get crafty?
You at least know where to start now, that being the form factor documentation.
If you’re looking for ideas on what you can do with a scratch-built PC, check out www.mini-itx.com, scroll down and look at the right sidebar. You’ll see links to many interesting – and fully functional – projects people put together.
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