Modding Cases (Aesthetic) - Any resources?

[imported_trajan]

Can anyone recommend any good resources on modifying cases? I'm thinking of doing some mostly aesthetic work, probably starting with modding a side panel to add a window, and maybe some etching or painting. Total, complete noob at this but willing to learn. I've googled it, of course, but its hard to tell what the "good" sites are!

Also, does anyone know whether there's a big difference in terms of working with steel vs. aluminum? Aluminum is obviously lighter, softer, and I'd imagine easier to shape/drill/cut. That said, is there a huge difference practically speaking? Like, if I got a dremel, is the difference in material immaterial, or is it still going to be a big factor?

Thanks for any help!!

 

[Zap]

Originally posted by: trajan
if I got a dremel, is the difference in material immaterial, or is it still going to be a big factor?

Softer = easier

I've had to do work on some stainless steel. Totally made me appreciate the softness of aluminum.

 

[Painman]

You might help yourself out by choosing a case that has a windowed side panel to begin with -- plexi is way easier to cut than metal, and if the case vendor is one of the bigger/better ones, then they can sell you a cheap replacement panel if you really screw up. Or you can just get some replacement sheet plexi @ the hardware store.

In my experience, dremeling large amounts of any sheet metal (such as cutting for a case panel) is awful, unless you have a jig that lets the Dremel behave like a router. Keeping your lines straight is tough (and you only get to cut once), and Dremel cutting bits for metal produce shrapnel like you wouldn't believe. The shrapnel gets flung everywhere due to the speed of the bit. Expect that any items of clothing you wear while working will get ruined due to micro-shards of metal becoming embedded in the fabric. WEAR EYE PROTECTION. You WILL get shards of metal stuck in your eyeballs if you don't.

 

[legoman666]

Dremels are terrible for cutting lines. The only time they should ever be used is for situations where a regular saw won't fit. Otherwise, use a mitre saw, radial arm saw, jig saw, scroll saw or band saw. Anything but a dremel. You might want to take a look at the project logs over at bit-tech: http://forums.bit-tech.net/forumdisplay.php?f=42

Aluminum is hard to paint. Wood is nice. Steel is easier to paint, but a PITA to machine.

 

[imported_trajan]

Got it, thank you all for the advice. Especially re: metal shards. :shocked:

Maybe I'll scale back my ambitions a little and get the side panel to begin with, as recommended!