I was pleasantly surprised, Lexan was not that hard to work with. It doesn't seem to shatter and I was able to cut it on my table saw with a standard blade. It was also pretty cheap and available at home depot. It scratches pretty easy though so I kept the protective covering on until the last second. Filed the edges with a hand rasp.
I used some standard stand offs that I had lying around from a motherboard and screwed them directly into the lexan (after pre-drilling of course). For the corners I got some stainless steel cap screws with wingnuts and nylon spacers from the hardware aisle.
Total cost for the case was about $6.
It's sitting on my desk and pretty much everyone who comes in my office comments on it. Most folks ask if it came from a kit which I guess is a good thing.