case modding / dremel accessories

[Fullmetal Chocobo]

I'm not quite sure as to what tool to use for what. I have two things that I need to cut.
1.0mm thick steel (my case), and then 1/4" thick plexiglass (case windows). Anyone recommend which ones to use for these materials? I'm aiming to not mess these up when I mod them... 🙂
Tas.

 

[gorcorps]

dremel tool in my experience doesn't cut metal neatly, but I don't have a really high speed one nor the correct attachments

 

[swtethan]

fine toothed dremel tool.... smooth out the edges

 

[lobadobadingdong]

score your cut, and use the dremel to cut slightly inside the score with the thin metal cutting wheels, them move out to the scoring as close as you're comfortable with the cutting wheel, then use the heavy grinding bits to get you all the way to the scoring, finish with increasingly lighter grinding bits and/or the heavy sandpaper rollers. (btw for round cuts, it's easier to use a metal hole saw and a drill press, and then smooth the edges)

edit: one more thing, learn how to do this on scrap metal before trying it on your case, you'll be happy you did.

 

[imported_adam1234]

For the metal use a dremel tool with the cutting wheels like everyone said, for the plexi, use a scroll saw with a very fine toothed blade and mask of the area you plan to cut first with masking tape to prevent the plastic from splintering. Make sure to hold the plexi tight to the platform on the saw so it can flop up and down, this is what causes it to crack. Once cut, use sandpaper before removing the masking tape to smooth the edges to your liking

 

[Zepper]

I use the 1/8" carbide cutter (#9901) for raw cuts on metal (use a 1/4" drill to start a hole if there is no place to start from) and then I use the cutting wheels and grinding stones to finish. Be sure to use something like Rustoleum primer to coat any bare steel edges to keep from rusting - aluminum generally doesn't need any coating unless you messed up the surrounding metal.
. Use the Dremel bit guide on their web site for tips and info on how to use the bits, at what speed, etc.
There is also a dremel modding guide linked to in the Case Modding/Vendors thread (which is supposed to be a sticky thread but has been spotted floating lately) and other threads that is quite useful.
BTW, this stuff has already been convered numerous times in other threads. The Search function of these forums is your friend. It gets tiresome seeing the same d__n questions over and over.

.bh.

 

[Jeff7]

If you use a cutting wheel for anything, get the more expensive fiberglass reinforced wheels. The standard things and even heavy duty wheels won't last long at all against steel or aluminum.

 

[Fullmetal Chocobo]

Originally posted by: Zepper
I use the 1/8" carbide cutter (#9901) for raw cuts on metal (use a 1/4" drill to start a hole if there is no place to start from) and then I use the cutting wheels and grinding stones to finish. Be sure to use something like Rustoleum primer to coat any bare steel edges to keep from rusting - aluminum generally doesn't need any coating unless you messed up the surrounding metal.
. Use the Dremel bit guide on their web site for tips and info on how to use the bits, at what speed, etc.
There is also a dremel modding guide linked to in the Case Modding/Vendors thread (which is supposed to be a sticky thread but has been spotted floating lately) and other threads that is quite useful.
BTW, this stuff has already been convered numerous times in other threads. The Search function of these forums is your friend. It gets tiresome seeing the same d__n questions over and over.

.bh.

I did search Zepper. And only two came up when I searched, and I wanted a new opinion on it. You mentioned a Dremel Guide on their site--which site? And they let the Case Modding / Vendors thread die. They unstickied it, and it fell away. I wish it was still here, least I wouldn't have had to ask this. Sorry to bug you with another damned question about the same sh!t, but I couldn't find it when I needed it... Thanks for the info nonetheless though. 🙂
Tas.

 

[alexXx]

i ruined a dremel(overheated it) trying to cut through sheet metal. There are better ways

 

[Fullmetal Chocobo]

Yeah. It took forever just to break through a test sheet of the same material as my case using the cutting discs. I'm thinking about just marking it, and having it cut. I'll use the dremel for the plexiglass...
Tas.

 

[Zepper]

Dremel bit guide (also called the bit catalog) on dremel web site... :roll:

.bh.