Cutting side panels...

[ToXiCRaGE]

What do you use to cut openings in your side panels, or what do you use to cut any kind of designs? Regular Dremell? How hard are those metal cases to cut - is there much resistence applied by the metal?

I was thinking of making a simple mod to the side panel of my comp and replace the hole with a plexi glass or somehting like that (or other plastics). I would also like to put some lighting into the case - prefferably a gereen/yellow combination to give it a "toxic" D) look.

My case is painted black, not the best painting job (a good one though) but hey, it was my 1st mod as well as my first attempt to paint a computer case.

Anyhow, how would you cut a hole and how do you attach the plexi glass with the nice finish around the edges?

Thanks.

 

[Packy]

This doesn't address all your questions, but I've noticed that most professional-looking side panel mods tend to be cut using a jigsaw rather than a dremel. Dremels tend to walk or skip and the worst moments while cutting... they DO make pretty sparks, though

Here's a thread I started recently about a "nibbling" tool that can be used to cut metal as well.

When you cut it out, make SURE to tape a mask down around the spot for the new hole so as to prevent chewing up your paint job by the jigsaw (if you use a jig).

To get a nice finish for the plexi, it might be the easiest just to buy a window kit... they come with the rubber molding that you'll need to make everything look professional.

Not the most in-depth answers, but hey, have fun

 

[pearlJammer]

i recently cut a hole in the side of my case for a fan using a Dremel and one of those cutting wheels. i used Dremel bit #456 with an older version of the Dremel #2850-01 Two-Speed MultiPro Kit on the high-speed setting (35,000 rpm). i don't know if that's the bit that you're supposed to use to cut into sheet metal but it worked... though i did go through several of them. the panel i cut through was one of those old steel panels but from what i understand (i don't have any first hand experience), aluminum is suppoed to be easier to cut through. it did take a little bit of pressure to get the thing started but not a whole lot. be careful though as there were a lot of sparks flying and a bad smell. you might also want to wear ear protection as well...

to finish off the edges, i just used some sand paper and elbow grease to smooth it out but i suppose you could use another one of those Dremel bits. i just needed to get the burrs off. if you want a more finished look, you could get some of that flexible molding. i'm sure you could find them in different colors. or if you're really skilled with the Dremel, or just have the patience with sand paper, you could even bevel the edges off.

as for the window, i can't help you much there. two-sided tape on the inside of the panel might do the trick. you could even go as far as drilling holes and screwing it down for a more secure fit. not sure how well plexiglass drills though...

good luck

 

[Packy]

Tom's Hardware has a very detailed article on cutting and installing a case window. Enjoy

 

[Zim Hosein]

Originally posted by: Packy
Tom's Hardware has a very detailed article on cutting and installing a case window. Enjoy

Thanks for the link Packy, it's much more informative that the directions that came w/ my case window, much appreciated

 

[KouklatheCat]

I used a dremel tool with fiberglass reinforced cut off wheels on my steel case and a jigsaw on my aluminum Lian-Li. I worked slowly with the dremel and didn't have a problem with skipping.

 

[dum]

i use a dremel with reinforced cutoff wheels for all my cutting. They work pretty well as long as you don't want to cut out a circle. The easiest way I've found to do that is use the cutoff wheels to cut out a hexagon type shape and finish it with the grinding stones if the circle is large enough. If it's not I use a drill to start the circle and finish it with the grinding stones.

since your case is already painted, put down a very thick mask of tape around the cutting area (at least 3 layers of tape). If you don't and use the dremel the tape will either start to come up or melt away and then the heat on the metal from the cutting will burn the paint and ruin all your hard work.

I would also not recommend using wd-40 or any kind of lubricant on the case while cutting. If you get into a bind or you start seeing smoke, stop for a moment. The case I'm working on now has some terrible looking spots on it now because my dad was insistent on watching while I drilled out some holes and starts spraying wd-40 everywhere to make sure nothing overheated. The wd-40 caused the stickiness on the tape to dissolve exposing the panel. Even after heavy sanding and at least 4 coats of paint, 2 rubbing compound and 2 polish those spots still look dull.

To install the window I've used the rubber stripping before but now I just use 3M double sided tape. If your cutout doesn't meet you satisfaction around the edges the stripping is nice because it will cover it up, but it is such a pain to get installed without cutting yourself or scratching the panel. The tape is easy because you just stick it on the panel and put the glass in place. The only problem with the tape method is that the glass sits farther back than it does with the panel so you have to make sure you have clearance all around.