So, this is happening, although with a few caveats.
I received a package from Adafruit with most of what I need to complete this. I did a dry fit of some parts, and a fair bit of sanding and filing of the case I printed. The PLA sands fairly well. I had good luck knocking down the sharp edges and flash with 150 grit paper, and then moved to 400 grit for smoothing. I tried using a powered sander on a previous project and that ended in disaster as the PLA just melts with the friction. On this first unit, as it seems I'm going to be making a few of these, I'm considering just applying a clear coat as I like the look of natural PLA.
It was confirmed by a friend that the PI2 will not fit this case. I think for the first one, I'm going to order a Pi model B. In the meantime I will try to modify the design to accept the Pi2/B+ footprint. My Pi2 has not yet arrived, and I have yet to order a Model B+ to confirm the footprints match.
Some may recall that I managed to break the USB connector on my PI Model A+. I repaired the unit and it is working correctly. While I was sanding and dry fitting parts on the PiBoy, I printed a case for the A+. I am now printing a bracket that will attach my cell phone to a tripod. I took me awhile to figure out how I was going to use a 3D printer, now it seems every project I work on has some connection to 3D printing. I would encourage those of you "sitting on the fence" to go ahead and get one, you'll start to think about your projects differently.
And now, the photo. The controls are temporarily affixed with cellophane tape. The battery, screen and power switch are 'snap' fit. The case halves screw together with 4 6-32 screws. A 1/4" drill bit was turned by hand in the large countersunk portion of the screw holes to allow the screw heads to sit below the surface of the case. A countersink was also used on all round holes to chamfer the rough edges. When assembled the unit feels very smooth and comfortable and it has some weight to it. I'll order a Model B this week and get this one buttoned up.
Regards,
Scam