Hello Cerberus73, i read your first post just a while ago, and went thru Zetr0´s awsome 1200 x86 project! Very Cool Stuff!!! Five Stars!!!
I too stayed away from amiga scene from quite some time, still catching up, and learnning and relearnning everyday!
An "Amithlon" x86 is a good solution!
I guess One could made the case mold, and then replicate it in fiberglass.
Like this yet rough example (Be careful, there´s Madness in my thinking
)
Polyurethane foam can be used to shape the case mold.
Could submerge an amiga 1200 case in liquid vaselin, to prevent the foam from glueing to it. Some pieces of plastic could also be placed with silicon glue in the case opennings to make it more like a single piece and facilitate later extraction.(Like keyboard opens, vents, back opennings, floppy drive/pcmcia etc..)
Could then use a hard paper card box to place the A1200 case in, only one part at a time...if possibly suspended in the middle with some nylons.
The Card Box will then force the foam around the Case and shape a new mold.
After two hours or so its ready for extraction.
This is also a mix of Brainstorming...but the above process works in similar things.
The nice thing is that One could make several custom fiberglass Cases with one mold.