Hard-Wearing Aluminum Laptop Case

I have a leather bag I like a lot. But I also have a small computer. It’s kind of dumb to carry around a mostly-empty bag.

Normal Size Bag

Tiny Computer

But…

I also have a ZERO Halliburton Slimline Aluminum Attaché Case (you better believe I’m typing the é). My dad gave it to me maybe 20 years ago. I have no idea where he got it, but it was used. The friction hinge was broken so the lid wouldn’t stay open, and I didn’t do anything with it for a long time.

Now check this out:

All it took was

  1. A Zero Halliburton Super Slimline Aluminum Attache Case in Silver ($485 from Amazon)

  2. 2 pieces of ½”case foam ($22 from Amazon)

  3. A matching screw to repair the hinge ($9/set from Amazon or $0.14 from your local hardware store)

I bought two sheets of ½ inch polyurethane. One of them is only cut to fit inside the case and accommodate the charger. The computer and video adapter sit on top of that piece and the 2nd piece is cut to fit them. The document pouches in the lid have room for wireless headphones, a USB speakerphone, and two USB cables.

It took me two tries to cut it because I stink at cutting foam. I had to throw away my 1st attempt. It turns out that a utility knife and lots of patience work better than an electric knife.

And THAT’s a case I can live with.