Of course with the way I've dinged and smashed my case up thicker is better.

It occurred to me that the screen *could* be bumped up to a larger size even. ( 19"? ). The extra room could house some killer speakers, more batteries or something, not complaining about the existing ones though.

The key thing is to get the mounting points for the original case and translate them to CNC codes. Once you have an acceptable case template you could do just about anything. This sounds like a group/open source candidate.