yeah i know how to make one
http://forums.anandtech.com/showthread.php?t=2036435&highlight=hyperlite
But it now has two 120mm slipstreams in the front and much better lighting.
Frankly, i think if you have any woodworking skills, that might be a good avenue. As long as you don't use like, burly maple, the weight will be manageable, and if built properly, would be very sturdy. Though yeah, nothing beats metal for strength/thickness. I think using aluminum angle and rivets would be the easiest/cheapest/lightest way to accomplish this.