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Case Cutting Tips?

S

Synomenon

Supreme [H]ardness
Joined
Feb 10, 2007
Messages
7,662
So I finally got a chance to put this Thermalright HR-03 on my EVGA 7950GT KO Superclocked today:

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Looks nice and keeps the card very cool (even without a fan). Now I need to cut my case cover. I've never done this before. I do have a Dremel, but I've never used it to cut metal before. My PC is a Shuttle SD39P2 XPC. The case cover is a "U" type shell that you slide on over the chassis and secure with thumb-screws:

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Which cutting wheel should I use to cut my SD39's case cover?

I need something to practice on first. Where can I get metal similar to the SD39's case cover to practice on? The case cover is pretty thin aluminum.

When I'm ready to cut my SD39's cover how should I do it? Do I need to put masking tape over the parts of the case cover that I'm going to cut?

What's the best way to measure the area I need to cut (I just want to cut a rectangular opening for this Thermalright HR-03)?
I'm going to be putting edge molding on the cut edges of the case later on. The corners of the rectangular cut (near the front) need to be rounded so I can get this edge molding all the way around the cut nicely. The cut will go beyond the back edge of the case cover since the HR-03 goes past the rear edge of the case cover.

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What's the best way to keep the case cover secure (without damaging it) when I'm cutting it with my Dremel?


Any tips / advice on this would be very much appreciated.
 
I usually use my jigsaw to cut the panel and my Dremel to clean up the cut. If you go this route, mark your cut lines and mask off the area around it so not to scratch the surface with the faceplate. I usually make a wooden support to allow the panel cover to be supported, while providing a cutting slot for the blade (about 1/2" gap). This eliminates vibration and reduces the possibility of damaging the cut surface. Take your time and don't rush the cut. :)
 
Yes I do have goggles. I've used my Dremel before, just not for case cutting.
 
If using a Dremel you want to use the reinforced cutting disks. They have a grid like the ones in the image below.

Personally I use a C-clamp or large Vice Grips to attach my work to the bench. Keep the clamp close to the work area to help prevent excessive vibrations.

 
Would Dremel's diamond cutting wheels or the metal EZ-Lock cutting wheels make cutting my case easier? One of my friends has these and I might be able to borrow them. Or are the fiberglass reinforced cutoff wheels the best to use in this case? There's also the matter of not scratching my case with the clamps or vice grips. Can I put a piece of cloth between the case cover and clamp to keep the clamp from scratching the case cover?
 
#1 Cutting tip for anything:

Measure twice, cut once.

Best of luck to you! Show us your work!
 
Ok I'll finally have time to do this tomorrow. When I do it though I'll be cutting on the inside-side of the case to avoid accidentally messing up the paint on the case. Should I put masking tape over the area I'll be cutting? Or on the outside of the case (over the area I'll be cutting)?
 
Masking off the area is usually a good idea. Don't cut through the tape with your Dremel however. Good way to clog up the disk.

Try to trace your line with the cutting disk first. Make a shallow channel instead of going all the way through from the start.
A lot easier to follow your line that way.

As always - - SAFETY FIRST
 
Thanks for the tips guys. Here's what I did:

- Cut case cover for video card cooler. Added chrome edge molding around hole.
- Cut top rear “lip” of case to allow it to close over new 70mm fan grills on the rear.
- Cut hole in rear hard drive tray to mount a Scythe 100mm Kaze-JYU super silent fan that blows down onto PCI card and video card
- Placed cold cathode inverter next to Scythe fan in the rear hard drive tray
- Put cold cathode under the top of the frame, above the video card
- Cut bigger holes for 70mm fans that replaced the stock, rear 60mm fans
- Slipped BIOS savior switch into one of the slots used to mount the PN18 wifi module in the frame near the top rear of the case (not pictured).

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Where did you get the silver lining in to take up space where you cut the piece off? I'm trying to figure out something like that to do whenever I chop up the top of my case to fit in a 140mm fan.
 
aeonrevolution said:
Where did you get the silver lining in to take up space where you cut the piece off? I'm trying to figure out something like that to do whenever I chop up the top of my case to fit in a 140mm fan.
Click to expand...

I picked some up at an auto parts store, some people use it to as trim on their door edges.
 
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