I have made IO-covers before, both with aluminium and acrylic. The technique is a bit different from the two materials, but how you measure it is the same. In this guide I will show how I make one in 2mm thick aluminium, however I will also explain how you do every step with acrylic.

Lets start by measuring how big the IO-cover is going to be. First of all we have to start with measuring the length, that is pretty straight forward, just measure from the outside of the port on the top of the motherboard down to the outside of the last port on the bottom of IO.

For the width we need to measure the widest port plus the one with the most height, put those measurements together and add 2-3mm for the bend. If its to big after the bend it is easy to file it down.

Next thing to do is to mark out the measurements on the aluminium, or acrylic if thats your choice of material. To make the bend easier to do its a good idea to mark out where the bend is going to be.

For cutting out aluminium I am using a jigsaw and medium-fine blades, for acrylic I recommend really fine saw-blades as it will make it easier.