This is a laser cut enclosure design for the BeagleBoard Rev C. It's got access to the expansion header or alternatively a mount for a 9-pin D-sub for direct serial terminal access or to use as an auxiliary serial port. The whole thing clips together with some special Delrin clips for easy assembly as well!
Cut the black lines and etch the red ones. All the components except the clips are cut out of 3mm acrylic. The Delrin clips are cut from 1/8" Delrin sheet stock.
Instructions on assembly with tons of pictures can be found here:
More details on the clips here:
You can get a kit of this thing here: