Well a couple of good nights on this & I'm pretty much done. It's currently running fullscreen iPlayer with Speedfan monitoring temps to check the airflow is ok (which I think it will be) 64C after a while which is warm but within spec
Decided to avoid the hinge idea as it was proving too complicated, used a couple of brackets from an Ikea flat-pack screwed to the box to mount the screen. Covered the box in the stuff I got from B&Q designed to be blackboard vinyl which works well.
So...installed with the front off
Bit of a close up..
To get a sense of positioning
I've covered a cardboard sheet in the covering to match the box & cover the internals, on the below pic it looks wonky/ribbed (ooh-err) but that's just the flash picking it up, when looking at it under normal light you can't see any of that The cutout is for the power button.
Another side shot
A final shot in all it's glory!
I kinda lost track of costs but here goes...
1st Laptop - FREE - Scrapped
Final Laptop - £45
HDD - Swapped an Xbox for it. Scrapped
Frame - £8.50 Scrapped
New Aluminium Frame - £24
Dremel - £10
Dremel bits - £17
Black 'seals' - £2.50 Scrapped
Black mesh tray - £5.61 (Too small, waste of Amazon credit that was!)
Acrylic sheet for screen - £4.30 Scrapped
USB Hub - £1
Tape - £1
Wood - FREE
Screws - £1
Hole drills - £1 Never even used
Black covering - £5
Assorted nuts/bolts/brackets - £3
= £128.91
Of course I've still got the Dremel/bits & bobs so it's not exactly the 'real' cost but it's not bad