Devcon makes an epoxy spesifically for plastic that should work OK, You may want to check some of the hobby stores and ask what modelers use to attach canopies to their aircraft models....that would bond very well and not cause the plastic to mik over like cyanoacrylates will. However I don't think you will be able to carry around a fully acrylic case and not have it fall apart....even the best of plastic bonders will let loose under shock loads and constant vibration, those cases tend to be more for show than anything else....and I have read of them giving people fits in the past.
1/2 in plexi would be strong enough as would 3/8, but really heavy, the problem I see you having is gluing it together without causing the plexi to turn a milky color. Drilling holes in plexi will require a special bit for plastics that has a different angle than standard 118-135 degree bits....you need a bit with a 150 degree angle, and you still run the risk of having it crack or craze in those areas. The Devcon epoxy for plastics will hold, but if I remember correctly it turns into a slightly yellow color when cured. PS-30 and Weld-On 40 will not discolor and are excellent for gluing plexi (heck, I use the stuff for airline work !) be cautious not to mix bubles into them, (if you do let it rest for 10min....it has a 45 min working time) and make sure the plexi is perfectly clean, (that means no fingerprints...the oils on your hands will prevent bonding) use simple soap and water with a clean cotton cloth. Good luck and let me know if you need any other info
Drill bit holes and put in little metal bits and glue em tight with super glue. Look at some cheap cabinets at target they are made the same just with wooden bits and wood glue but the same concept. For the corners, if you want them air tight, i would get some clear building adhesive like latex(in a tube) and seal it up.
the problem with gorilla glue is that it bubbles up and looks ugly if it would do that lol my whole case would be made out of it haha
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