Case Mod for Slimmer PSU?

[FitzGerald]

Hello,
I've never posted in the case forum before... I have a question regarding a HTPC-sized case. Last year I bought this case. I've got a 6150 motherboard with a AMD 3700+ and Zalman Cooler (Zalman was shortest HSF I could find). Note, the stock PSU is only 200W, and it's actually a Flex-ATX form factor.

Initially I bought a Seasonic 300SFD thinking it would fit (note the OEM power supply is also SFX) but that was incorrect. I bought the SPI270LE instead. The sparkle is actually slimmer than the OEM PSU.

When I install the sparkle PSU, there will be about a 40mm space that is open. What's the easiest material to use to plug this (alumnium)? Where could I go about buying it? I imagine if I tell them what size to cut it to and where to place the screw-hole this could be a simple thing. Maybe I don't even need to worry about that gap.

I suppose another question I have is what is the best tool to use if I wanted to cut some vent holes on the top of the case... I think my CPU might get too hot since there is only a 60mm fan in this case, but I'm not sure. I'll be using this computer as a HTPC application.

 

[Zepper]

Hole saw for fan holes. Shouldn't be that hard to find the correct PSU. Measure the old one and buy new with the same. There are two arrangements for SFX: one has the short side to the rear and the other has the long side to the rear. Looks like your case is short-side rear, so one like this:
http://www.ewiz.com/detail.php?name=PS-2725J2G -should do it. Enermax makes a nice one too.

.bh.

 

[FitzGerald]

Yeah. It does have the short-side to the rear. I already measured it to be 63 mm x 83 mm. Actually the one I've got is 81 mm by 40 mm... so I just need to add some type of 80 mm x 20 mm piece that will block off the case from the outside. I actually think I could get buy without putting anything in the back.

I was thinking of using a hole punch for the vent holes on top...

 

[FitzGerald]

Doh! I think I could just use electrical tape to tape up the 80 mm x 20 mm space that I'll have. That's a cheaper solution... it's in the back of the case so no need to be elegant. (Can someone please tell me this is a bad idea if it is).