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Is this a legit copy of XP for which you have a disk? L

Using both a super fine iron and nickel mixture could give you some interesting results. :-)  

 I have already done some google searches, but with no success. The circuit board would only have to have the smd chips pre-soldered:  I could do the rest. I guess enclosure is the wrong word.  I mean more like a bunch of laser cut parts (most plastic, but some metal).

Look for "electronics assembly" or "PCB fabrication".  You'll get lots of hits right up front.  I'm guessing you haven't done any such search, or you'd already have options, and you'd be asking us questions like "do you know these yahoos?".

http://fotosa.ru/stock_photo/Thinkstock_JI/p_311992.jpg looks kinda like that

It's worth a try - use the finest iron powder you can.

you want them to solder it for you? well i know sparkfun can make custom enclosures, except theyre a bit pricy also, golden pheonix will make and solder pcbs for you, but again, somewhat expensive

I'm hoping someone here knows something about spray paint. Specifically why some spray paints seem to take forever and a day to dry. In the attached picture the paint on the left (Metallic) dried quickly, within about 45 minutes whereas the paint on the right (Gloss Protective Enamel) is still so wet at 24 hours that I can scratch it with my thumb nail. FYI, I used both paints, one right after the other, on the same kind of metal. So if...

I'm taking a guess from experience, you could really look this up but the metallic paint is probably fine metal dust that is in a clear laquer or carrier that just "glues" it down to the surface.  There is not much to evaporate or cure off.  With your gloss, the clear shell gloss needs to cure and harden to give you a wear layer.  Pigment is suspended in that making it take longer to...

i would say a xe withe a knife in the handle