I used this material for the most of the case of my portable Mega Drive.
http://www.design-technology.org/plywood.htm
You see it's made by pressing a number of layers together. I used the one made of 3 layers. Each layer is 1mm thick so totally it's 3mms. It's stronger than regular wood because it's made according to this theory:
http://www.engin.umich.edu/class/bme456 ... ucture.htm
Surely, it's one of the lightest and the strongest materials you can use. Also it's easy to shape this material by using your hacksaws, x-acto knives, and sanders. Now, take a small search by visiting your local carpenters especially the ones who make doors and kitchen furniture.
For the guys who haven't checked my work yet, here it is:
http://benheck.com/phpBB/viewtopic.php?t=17415
The material used for SEGA SAHNE... 'plywood'
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