I spent most of the morning forming/bending sheetmetal to make the enclosures. After two attempts, I was still not satisfied on their fit.
I decide to make them out of fiberglas instead. I shaped a block of wood to fill the opening and applied clay around it. This was to form the mold for my positive cast that I would apply the fiber and resin to.
At this point I thought maybe vacuum forming would make a better part for this application. The next log entry goes in to this in more detail.