Case Modding

[abs0lut3]

I have an AMS Gmono case which I think has a flawed front air intake design. I can tell if an 80mm fan was put in instead of a 120mm fan that I have on it at the moment that the air was just going to be redirected from the empty holes the 80mm wasn't covering but with the 120 covering all of them, there is little or no airway for it to suck the air from.

Since the front end is layer like this: 1/4" plexiglass and thin plastic to give it the "black" look then the bare steel front frame, I would like to cut the plexiglass and the plastic cover at the same profile as a 120mm fan would be as well as cutting the metal itself so I would have a completely open intake what will be covered by a foam filter and a finger guard.
Picture of the front end assembly is Here. and the picture of the front end fully assembled is Here.

OR

I would purchase one of those Aerocool's new 120mm Turbine fan to give it a turbine look/effect with the filter mounted behind the fan.

The question is what have you all use to cut the plexiglass with? I have friends who had tried to cut it with dremel. It didn't work well. The dremel rotary cutter just ended up melting other areas that the cutter was supposed to cut. RotoZip comes to mind but buying it only for this purpose does not do me justice. I might have another case to cut but that makes it only two purpose and then it is off to storage for...storage.

Any other suggestions?

 

[elpres05]

First check out,

http://www.sbrlabs.com/MAIN/SBR_CASE/SBR_Index.htm

The guy there says he used home tools to bend and cut the plastics, even the thicker ones.

I've once tried a custom tool which is nothing mroe than a piece of steel ending on a very sharp edge. Mark the lines and strip the plastic with each stroke. Once you give it a few shots, bend the fractured area to remove the piece. Really, its the simlest method and it works wonders, best of all, you don't even get flawed edges, they are all plain.