Yesterday i made this stainless steel belt case for my newly acquired iPhone 4. Like most of you, I wanted to protect it from screen damage, but I have an affinity for SS, so I made it out of scrap SS I had picked up some time back at the salvage yard for just such a project.
Stainless is a difficult metal to work with, but well worth the effort. I welded it with my MIG wire welder using SS wire and ground down the tack welds. I was having trouble getting the front "mirror smooth" so I did some "engine turning" on the front. I used a sandpaper roll on my milling machine and it came out better than I expected.
I lined it inside with thin leather on the front, sides and bottom. A trial fit told me it would be too tight using the .070" leather, so I use a cloth backed vinyl upholstery on the front that measured .040. I used contact cement to glue the lining inside. The phone fits perfect with a little bit of drag and it is easy to remove using my finger through the hole in the bottom..