Update on my custom external box...
 

Case is constructed of the following materials:
-3/4" alluminum angle for the frame
-1/8 rivits
-Watts A-390 1/2"X1/2" Barb Adapter
-Watts A-385 1/2"X1/2" Barb Adapter

Watercooling components inside of case:
-77' Bonneville heatercore
-4 120mm 12VDC SANYO DENKI BRUSHLESS 5 INCH MUFFIN FANS 120MM
-Danger Den Bay Reservoir High Density Polyethylene
-AquaXtreme 50Z-DC12-T Mag Drive Inline Pump

Will seal all seams with silicon. Case will be constructed of 22 gauge aluminum sheets. Last side panel will be contructed of thick lexan. Anticipate this lexan side to be removable so I can have access to internal watercooling components. Plan on having a lexan interior panel to prevent heat from pump and powersupply from flowing to heatercore and reservoir. Will be using rubber groumets so tygon tubing can route through this middle lexan panel inside exterior watercooling case. Will mod this powersupply in external case to be slave to run pump and fans. Will have Watts A-390 and A-385 1/2"X1/2" Barb Adapters on rear panel of exterior case and system case to connect the two cases with one another. Will be purchasing blue LED case feet to put on bottom of exterior case so this external case will not scratch my system case. Will be painting all aluminum sides and angle aluminum black to match my Kingwin system case.
Before I finish this case this weekend, will the 22 gauge aluminum be strong enough to support the 77' bonneville heatercore? Also what would be the best paint to use on the aluminum? Duplicolor? Any other suggestions or input would greatly be appreciated.

http://img.photobucket.com/albums/10...3/DSCN1705.jpg

barbs being used..
 

barbs..

http://img.photobucket.com/albums/10...3/DSCN1703.jpg

layout
 

planned layout..

http://img.photobucket.com/albums/10...seproject2.jpg

That looks very similiar to something I had planned.... how long is your case? Matching the box up in size to my case, I found it to be about 2" too short to fit the pump and rad inside.

If you power everything off of the system PSU, you can fit everything in a much smaller case and won't have to worry about the added extra heat. Here's a pic of one I through together a few weeks ago.

http://img71.exs.cx/img71/1290/dsc012168sg.jpg
http://img65.exs.cx/img65/2515/dsc012362wp.jpg

120mm fan choice and template..
 

I will eliminate that middle panel. Plan on upgrading my enermax 475w psu to ocz 520 powerstream and will run everything off of this powersupply. I was going to use colder quick disconnects but opted not to. I decided to go with the brass barbs. Just got my email from the guy(dockguy) selling those fans at ebay, and their inventory is totally exhausted. Anyone else know where I can acquire some Sanyo Denki Fans? Will the Evercool Aluminum 120mm Fan be sufficient subsitute if I run them at 7v? Will this following template be a good model to go by for cutting out the fan holes? Also, a cd seems to be very close to 120mm for a template also. Which template would you use with the Evercool 120mm fans?

http://img.photobucket.com/albums/10...ntemplates.jpg

lexan sides completed..
 

Lexan sides are cut and will be pop rivited into place once case is primed and painted. Will cut 4.5" holes for 120mm fans this weekend. Will cut out bottom, front, rear, and top panel this saturday. Will post additionall pics as this case progresses.

http://img.photobucket.com/albums/10.../image0002.jpg

other side..
 

current watercooling I have on hand..
 

-77' Bonneville heatercore
-Danger Den 478 TDX w/ Brass top
-Danger Den Maze 4
-Danger Den Bay Reservoir High Density Polyethylene
-AquaXtreme 50Z-DC12-T Mag Drive Inline Pump
-15 ft Tygon tubing


http://img.photobucket.com/albums/v2...s/DSCN1712.jpg

Intel Pentium 4 3.2E GHz SL7PN E0 Stepping 800MHz FSB 478 PIN 1M
 

painting the parts...
 

Progress so far...
 

used a dremel to cut out the 120mm fan holes. Will post more update pics as work progresses:)

http://img.photobucket.com/albums/v2...s/DSCN1765.jpg

1 question: is the paint you used Al compatibile? AFAIK it's hard to paint aluminium properly and after some time the paint just falls down.

I primmed the aluminum with the proper primmer rust stop. I then used satin black rustoleum for the paint.