Excellent Thread.... i dont usually read these all the way through, but this one i have,. and will be watching with interest, not only because i too am an avid carboot sale visitor, but because of the attention to detail you have shown on what is a budget build (although i'd guess your time and paint budget is somewhat higher than originally planned !)
ANY MORE MAJOR UPSETS AND I SWEAR THE WHOLE LOTS GOING IN THE BIN
you have no idea how many times those exact words have floated through my head with many projects, not only pc related !
I'm surprised your dremel has lasted, i've blown up about 3 of their "pro" range ones, look very similar to yours, but mine have been black, i ended up buying a black and decker one from the bootsale for all the abusively hard work, and baby the dremel one so i dont risk blowing it up again, seems it liked to eat metal dust and short out the brushes and motor
... not good !
I could however cry that you are so far away, because i could have fixed that front panel filler plate in about 30 seconds including time to set my kit up.... i'd have stuck you 2 or 3 spot welds on the back of it to hold it and then you could fill the seam, or i could have welded it in all the way and let you polish the weld back before spraying it.... next time, run it down your local fabricators/car body repair shop..... or anywhere that is likely to have a welder, it will take them about 5 seconds to tack into place !... literally.
Excellent build, i'm impressed, especially with your patience with the cable braiding... those pins can be a nightmare, i usually use a sewing pin to gently fold back those little tabs so they are flush and will release the pin... remember they are not sprung steel, so you can fold them back one at a time, you dont have to do both at once, if there are even 2 on them... for the 24 pin plug, i use a very small watch makers screwdriver.
The LED work was impressive too, for me it was easy to understand the ways required for fitting them, as i have some back ground in this type of stuff, but as you said this was your first dabble in this you did well, and with some excellent help too
And yes, your right about the PCI card chrome back plates... sorry, time to crack out the paint tin again
keep up the pics and stuff, can't wait to see this finished