ABS chips getting everywhere. I still need to rig up the vacuum system to prevent this.

Cutting one side of the D-sub hole. This was a bit awkward as it extends into the thin lid, and the vice jaws aren't tall enough to hold the lid against the rest of the case.

The cut face on the lid is rougher than I'd like, but it is well hidden once the electronics are in place.

Checking the fit before I remove the case from the vice.

Electronics in place. The USB connector doesn't project as far through the case wall as I'd like, but it's enough to work.

All it needs now is a label.