Danny,
I have a suggestion for making u all your Molex connector holes in the PSU case. I use a tool called a "Nibbler" - it is for sheetmetal work and is used to make small inside and outside cuts by shearing very small amounts of metal each time you squeeze the handle. I use it in modifying Instrument Panels in small Aitcraft (Cessna, Piper, whatever). If you know an Aircraft sheetmetal worker, you can probably borrow his, otherwise, you can purchase one at this link: http://www.bizrate.com/tools-nibbler/?sc=1 . Look at the 1st item on the page P/N: 76011B , it only costs $25.55 US.
If you plan to do this sort of work fairly often, you will find this tool to be very useful. You can drill a .25inch hole, say in the center of your layout for the Molex connector, and then use the nibbler to to enlarge and shape it to the exact size and shape you want. It works on "inside cuts" like the hole for the Molex, and can be used for trimming the "outside" of a piece of sheetmetal to any shape you like.
I think you'll really like this tool... If you do not understand how it works, let me know and I'll take some pictures of one in use to show you how it is used, but once you get it in your hands, you'll see how it works and how useful it is gonna be...
BTW: I am watching your "project" with interest. Keep us "posted" with your progress.