DIY Macbook Air Padded Vinyl Envelope Sleeve for Less Than $10.00

While you may have dropped anywhere from $1800 to $3200 for a MacBook Air, you may still balk at a $30-$100 sleeve for it. I decided to take a literal approach and try to use a regular retail envelope to house my MacBook Air in safety whilst still maintaing the imagery of the Jobs keynote presentation.
The main reaction I have received from this sleeve is 'Huh? what's so special about a plain manilla envelope.... oh wow COOL!'...
If you pick just the right color of vinyl for the sleeve, then you will have a sleeve that is visually basically indistinguishable from a plain, manilla shipping envelope while offering your MBA a good measure of protection from drops and bumps and a good measure of safety by obscurity.

1 Scotch # 7974 Bubble Mailer Size 4 (9.5in x 13.5in)
I bought a 6 pack at Target for around $5.00.
Spray Adhesive (Krylon 7010 was used by me but others may work)
Elmer's Contact Cement
4 Sqft of automotive/uphostery vinyl in a color matching the envelope (@ 10.00/yd enough for 4-5 envelopes)
Scissors
Cutting Knife (better a upholstery knife/carton knife than a Xacto)
Heavy books (enough to cover full surface area of envelope with considerable overlap
2 Red buttons
1 ft Red waxed cotton cord ( purchased 12 ft at michaels for .99)
Thread (the heavier the better)
1 Heavy gauge needle (thick enough to punch through but thin enough to fit through the holes in the buttons with 4-5 threads inside)

Cut two 14 x 10 pieces from the vinyl. Cut one 10x3 in. strip from the vinyl. no need to be too precise as you will be trimming down all the pieces.

Spray adhesive on longer side (the side with the flap) of the envelope.
Align and place vinyl on flap side of envelope
Press firmly on full surface area with hands, making sure there are no bubbles/wrinkles etc.... Take special care of edges as these are recessed from the surface of the envelope
Place books on top of paper side of envelope whilst envelope rests on a solid smooth surface
Wait 10 minutes

Spray adhesive on short (Back) side of envelope
Align vinyl to the top of THIS side (you will be folding the bottom over so leave about 1' at the bottom for this
Press firmly on full surface area with hands, making sure there are no bubbles/wrinkles etc.... Take special care of edges as these are recessed from the surface of the envelope
Place books on top of the side that already has vinyl on it and rest on a solid smooth surface
Wait 10 minutes

Make sure bottom flap (the vinyl that hangs from the bottom of the short end of the envelope that you placed in step 2) is cut straight and perpendicular to the bottom of the envelope.
Spread rubber cement liberally on the inner part of the flap
Fold flap over and clean up any smudges of the rubber cement before it sets
Place book on top of bottom flap, wait recommended amount for it to set.

Remove waxed paper strip that says "TO REMOVE ADHESIVE REMOVE LINER" on the inside of the flap lid
Put the contact cement on the paper flap, take care not to get any on the bubble wrap
Place vinyl flap on the paper flap
Place book on top of flap, wait recommended amount for it to set

Trim all edges as close to the original paper envelope as possible

Sew the buttons at the appropriate places
Wrap waxed cord around top button and leave enough (about 6in.) so you can wrap around lower button

Download New Soul by Yael Naïm from iTunes:
http://phobos.apple.com/WebObjects/MZStore.woa/wa/viewAlbum?i=271590818&id=271590765&s=143441
Play on loop while you slide you MBA in and out of your new case!