Since the cardboard cutout was so simple to mount and the computer parts was fitted irl, I found some room for improvements. These include: Wider mobo tray to accomodate the previously poorly measured GPU, more cutouts for cables, lower total height where a few centimeters could be cut off here and there, the outside casing needed to be designed and PSU had to get an inlet for air in the bottom.
The changes I made have turned out great, and here is a small summary:
The cable cutouts might be too big than what is really needed but I'd rather have enough space to route cables neatly than having to squeeze too much in a small hole.
The total height is not more than three 140mm fans, whereas before there were plenty of room around the fans both on the bottom and top. When I recieve the fans next week, I will measure if they fit neatly or if I need to make any more adjustments. The fan holes have been widened and I need to come up with a solution to mount custom grills on the inside so that the fans shine through the chosen design. I also need to come up with said design (Help!?).
The front and back panels are made to fit less snuggly than the rest of the cutouts to enable easy removal when inside access is needed. They will need a mounting mechanism that holds them into place, maybe thumbscrews, maybe magnets...
PSU now has a fan hole from the bottom of the case. There are no mounting holes for it yet, but I am planning on adding a bracket where I can screw it in place.
The torus design turned out great! I used Illustrator for this. Basically made a circle, chose Effects>3D>Revolve, followed by adding a hexagonal symbol pattern I made earlier. Then I cleaned it up and added a splash of my own touch. The back panel, where the i/o board and HDMI ports are got a nice cutout that should be enough to fit my hand inside while attaching the cables. They will then be collected in the bottom of the torus pattern and run to my peripherals.
I am pretty sad that I don't know how to use a 3d program like Fusion 360, so now I just need to measure everything multiple times and keep the assembled picture in my head. When I explain in person, I have a small 1:5 model I made from some cereal cardboard box. It really helps with the point-and-grunt.
Next up is the mounting mechanisms for front-side and back-side panels, fan grills and their design, riser cable mounting holes, on/off switch placement, and probably more things I come up with along the way. I also need to make a new cutout and testfit everything again.
I also made a flow chart of sorts in Visio detailing where all cables will go to facilitate cable management!
Left to right: Back panel with large cutout to route external cabling through. Fan mount for exhaust fans. Mobo tray with indicator rectangles for two ssd. Fan mount for intake fans. Front panel grill for intake of fresh air, will be complemented with a dust mesh.
Center mount, will curve around the PSU shroud. The smaller two rectangles will be glued onto the GPU port to allow for two thumbscrews to attach te GPU to the case.
Front-side and back-side panels. Front will be cut from acrylic and back from plywood. bottom-left is the bottom plate and bottom-right is the top-plate.
Flowchart of cables and peripherals, I will use this to manage my cables neatly.