| I just got a piece of aluminum and measured some lines for were I wanted the bends. Then I cut some 45 degree wedges out of the corners. This allowed me to be bend the sides in at a 45 degree angle. To bend the sides in I just clamped it to a heavy shop table with a piece of angle steel on it to keep the edges straight. Then a used a hammer to bend it. Once I got the sides done I had the corners welded up and then I used a jig saw to cut the hole out. 
One little secret is that I heated it with a torch before I bent it. Notice in this picture there is a slight discoloration about 2 inches to center from the bends. 
Keep in mind aluminum is brittle, thats why I only bent it at a 45 degree angle. Its probably also best to cut the fan hole out after the sides are bent and welded so that it doesn't warp.
"Being forgotten is worse than death"
"The penguines are slowly, but surely stealing my sanity"...."sprinkles" "The ricer isle is equivalent to the feminine hygiene product isle in the grocery store...real men just don't belong there." BradZ (FL) 
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