This is an old revision of the document!
This is the latest iteration of the web-enabled thermostats I'm making for my home energy management system.
The case was milled in poplar using the CNC router, then stained and polyurethaned. The cover is made from acrylic cut on the laser cutter with openings for the touchscreen and also the radio chip (I'm planning to switch over to the ESP8266 wifi chips at some point but haven't gotten around to it yet). And the PCBs were designed in KiCad and the files sent off to China for manufacture (I use Smart Prototyping and have been very happy with the results and service.
The overall dimensions are roughly 4 inches square by a little over an inch deep, and they actually look quite nice when mounted on the wall. In my opinion, they look better (well, at least more interesting) than the white plastic store-bought models…
Please let me know if you have any questions; I would be happy to try to answer them. You can also get (a lot) more details on an earlier version from this Instructable I wrote a while ago.