Case cutting tips? (Finally got it done!)

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Synomenon

Synomenon

Lifer
Dec 25, 2004
10,547
6
81
So I finally got a chance to put this Thermalright HR-03 on my EVGA 7950GT KO Superclocked today:

http://www.rootminus1.com/free...cs/10057/DSCN1659x.jpg


Looks nice and keeps the card very cool (even without a fan). Now I need to cut my case cover. I've never done this before. I do have a Dremel, but I've never used it to cut metal before. My PC is a Shuttle SD39P2 XPC. The case cover is a "U" type shell that you slide on over the chassis and secure with thumb-screws:

http://www.newegg.com/Product/...0Pin+Barebone+-+Retail

http://www.newegg.com/Product/...0Pin+Barebone+-+Retail


Which cutting wheel should I use to cut my SD39's case cover?

I need something to practice on first. Where can I get metal similar to the SD39's case cover to practice on? The case cover is pretty thin aluminum.

When I'm ready to cut my SD39's cover how should I do it? Do I need to put masking tape over the parts of the case cover that I'm going to cut?

What's the best way to measure the area I need to cut (I just want to cut a rectangular opening for this Thermalright HR-03)?
I'm going to be putting edge molding on the cut edges of the case later on. The corners of the rectangular cut (near the front) need to be rounded so I can get this edge molding all the way around the cut nicely. The cut will go beyond the back edge of the case cover since the HR-03 goes past the rear edge of the case cover.

http://www.rootminus1.com/free...erpics/10057/Case2.jpg



What's the best way to keep the case cover secure (without damaging it) when I'm cutting it with my Dremel?


Any tips / advice on this would be very much appreciated.
 
I

indamixx99

Golden Member
Oct 17, 2006
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I agree with that. Dremels arent the easiest thing to use when trying to cut a hole in a case. At least from my experience.
 
Mo0o

Mo0o

Lifer
Jul 31, 2001
24,227
3
76
I used some clamps, kept it sturdy just fine. W/ a dremel just go slowly and file it smooth when you're done
 
A

abhong

Member
Aug 17, 2005
143
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when i tried my first cutting experience, i had access to my brother's workshop and i hoped it would go easy but here's the summary...

1) hand drill + round metal cutting hole bit
the bit is the one used to cut door knob holes on the wooded door, but a metal version... in a fairly large diameter... i think 100mm was the biggest i had at the moment.
drilling the pilot hole was easy but even with the pilot hole, the edges was messy...
clamping the panel before drilling will save you a finger or two...

2) drill press + round metal cutting bit
ok, so hand was messy, so i tried with a drill press... same thing... very messy edges.
perhaps if i used a sheet of wood in front and back side of it before drilling, it would result in better edges?

3) dremel... um... hand is not so steady and takes a long time...

4) knock out tool... this is by far the best to punch holes, but there is a limitation in size...
i have not yet seen a knock out that is big enough to create a 120mm blowhole... 80mm maybe...

laser cutting will be nice... but i hear they can be expensive...

look up laser cutting on google, you will find some...
also some websites offer cutting services...
 
aigomorla

aigomorla

CPU, Cases&Cooling Mod PC Gaming Mod Elite Member
Super Moderator
Sep 28, 2005
21,087
3,596
126
Need a fan hole?

the simplist is with a hole saw. You wont get any cleaner circle cuts without it.

The easiest to take off hugh lines, is using a jiggy. This will cut the straightest and also the easiest.

The easiest for small cuts, is a nibbler. But your hands will cramp up after a while. :p

The best with precision is a dremel with a tungston cutter. I noticed these guys cut edges really well, however you really need to wear safety eq. Flying metal is dangerous. But this is very very slow.


If you have a dremel and you want straight cuts, you need reinforced cutoff wheels. And be prepared to spend a lot of time. :\
 
9

996GT2

Diamond Member
Jun 23, 2005
5,212
0
76
I'd say go with a dremel with cut-off wheels (preferably the reinforced kind). I did that to cut out the small intake holes on my CM Wave Master, and it took about almost an hour to get through the very thick aluminum in the front. However, if you're patient and cautious, you'll get very good results.
 
Synomenon

Synomenon

Lifer
Dec 25, 2004
10,547
6
81
I need to cut a rectangular opening, not a hole. I've looked more at some other forums and sites and people are saying that nibblers warp the edges? Guess I'll just practice with my Dremel on my case and cut well within the borders of the actual cut I need to make, before making the final cut.
 
S

SinfulWeeper

Diamond Member
Sep 2, 2000
4,567
11
81
Yeah nibblers do warp edges. At least with the two nibblers I tried, no matter how small of a bite I took.
Dremels do solve the warped edge problem, but are a hassle to use.

Two things I never tried yet, but have considered in the past. Plasma cutting. Extreme overkill, but it would be the easiest once you find a plasma cutter. The other is using a jigsaw. Since it reciprocates up and down very fast I doubt there would be warped edges. But it is still a small possibility. They are found in any construction shop and quite often pawn shops.
 
VinDSL

VinDSL

Diamond Member
Apr 11, 2006
4,869
1
81
www.lenon.com
Originally posted by: IsLNdbOi
I need to cut a rectangular opening, not a hole. I've looked more at some other forums and sites and people are saying that nibblers warp the edges?
Click to expand...
Sorry! My bad!

I didn't read this thread closely enough the first time around...

Looking at your pics, IMHO no matter what you do, its gonna *look* ghetto!

Having said that, if it was me, and I was intent on going forward with the project...

I would butcher the panel using whatever method and cover up the boo-boos with something like this. ;)
 
VinDSL

VinDSL

Diamond Member
Apr 11, 2006
4,869
1
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www.lenon.com
Um...

That looks like a Shuttle SD32G5 to me - not a SD39P2 XPC!

Your panels have more holes than a Swiss cheese ;)

Whatta ya gonna do about those?!?!?
 
Synomenon

Synomenon

Lifer
Dec 25, 2004
10,547
6
81
Yeah, I know it's a SD32G5, just showing what someone did to get their card to fit with his case cover on. The only vent holes on my case cover that would be in the cutting area are the holes at the bottom of the case cover. The big square one up front is past the cutting area and the vent holes at the top are well above the area I would be cutting.
 
VinDSL

VinDSL

Diamond Member
Apr 11, 2006
4,869
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www.lenon.com
~Cool~

Well, cut your panel with a Black & Decker jig saw and cover the edges with automotive door molding! :D

Sounds like a plan to me!
 
Synomenon

Synomenon

Lifer
Dec 25, 2004
10,547
6
81
Well one of the things I don't really want to do is buy new tools just for this. Cheapo here. :p

Would the Dremel diamond cutting wheel make it easier to cut my case cover? I think one of my friends has a diamond cutting wheel I'd be able to borrow and use with my Dremel.
 
WoodButcher

WoodButcher

Platinum Member
Mar 10, 2001
2,158
0
76
Diamond blades are for stone, tile, masonry and glass. Use a holesaw on the drill for round corners and an abrasive wheel for the straights. Back up the cut w/ double sided carpet tape and wood. Heat will damage the paint so cut inside the line and finish with a file. Vin's tip about the trim is an easy way out, or repaint. I use a 4' grinder of chopsaw for mot of my cutting but these are not common household toys. If you can borrow either the blades are cheap, 5 or $6. Bad things happen fast so be careful and good luck.
 
VinDSL

VinDSL

Diamond Member
Apr 11, 2006
4,869
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www.lenon.com
Heh!

Dude! Anybody look up the prices on these cases?!?!?

They cost as much as my Mountain Mods U2-UFO Opti 1203... which everybody thinks is ridiculous! :shocked:

On reflection, I wouldn't be cutting jack...

Why are these things so expensive?

LoL! I thought they were toys...
 
Synomenon

Synomenon

Lifer
Dec 25, 2004
10,547
6
81
Ok, so I'll finally have time tomorrow to try this out. I'll be cutting from the inside to avoid accidental scratches, etc.. Should I put masking tape over the area I'm going to cut or on the outside of the side I'm going to cut?
 
WoodButcher

WoodButcher

Platinum Member
Mar 10, 2001
2,158
0
76
I would tape the side of the line you wish to cut to protect the good, and the initial cut should be inside of that. 1/32-1/16" and clean the rest w/ a file, Cut on a table or work bench covered with card board to avoid scratching as you move it around on the table. Work clean, keep a vacum handy and you won't slide tour case around od metal filings and grit from the wheels. Last but not least, If your using a dremel take your time, the tool is slow so don't try to rush.
 
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