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Cutting a case is hard!!!

R

redman223

Gawd
Joined
Oct 28, 2006
Messages
1,013
I have went through 15 cutting wheels (I bought the 105pc kit from Harbor Freight for 6.99) so far and have only made 2.75 squares so far! (I still have a little bit left to cut on the third one lol).

What are the best ones to use for cutting metal? The kit came with 30 black wheels 30 brown wheels and 5 big black wheels with fiberglass reinforcement. I have only used the black ones so far, but just switched to one of the big ones.

I still have some MAJOR cutting to do...I might have to spend 6.99 and get another kit haha.

I will post pics when finished, as I am modding my case to fit 2 Accelero Xtreme 8800 coolers. These things are huge 3 slot coolers! I have to cut off the metal lip on the bottom of the motherboard tray on the Stacker 810, and then have to modify the bottom of the case so that the PSU sits flush with the bottom, and not elevated 8mm or so (sitting on top of that wire mesh grill thing). Should look nice when finished, as I figured since I have it all apart and the tools out I might as well cut some other holes to clean up the wiring.
 
For big cuts use a jigsaw.

I dont know why your burning up so many cutting wheels.

Id invest in the fiberglass or what ever enhanced ones from dremal as there heavy duty and can go for a while.

Also what is your cutting technique you should just have the dremal barley touching the metal and have the weight of the dremal do the cutting and your hand just to keep it straight and avoid it from bouncing around.
 
go slow! if you are breaking a bunch of dremel wheels you need to make your cuts much more slowly. and avoid twisting motions which will flex the wheel and shatter it. if you do it correctly, you should be able to grind the dremel wheel all the way down to almost nothing.

also some people prefer to go against the rotaion of the wheel for what they perceive to be added stability...so since most turn to the right, start your cut on the right and slowly move to the left. if you go with the rotation supposedly you are more likely to slip and leave a nasty grind streak across the surface of whatever you are cutting. but this is really a preference thing. do whatever you feel comfortable with.
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Yeah you were right, I was going way too fast. After those 15 wheels I used up 5 of the reinforced wheels, but each one went all the way down to a little nub. I finally finished it all up, now I am just de-burring all the edges and grinding a few things down. Then I gotta test fit everything and see if I can start putting it all together, or if I have to grind more.
 
Wow this is getting harder and harder as time goes on.

I like the idea of using the jigsaw mentioned above, it would've probably saved me 2 or more hours. I had to call it a day since I gotta drill out some stuff, and I forgot to charge the battery. There is also a lip that needs to be grinded down, but I think I will pick up some metal cutting blades for the jigsaw and will use that instead. Should be ALOT easier and faster. Hopefully the damn card will fit after that, otherwise I am going to cut a hole large enough for the PSU to go through, and will use a piece of sheet metal to hold it up.
 
I suggest not using a dremel for much cutting. Little stuff sure. Know anyone with a plasma cutter?
those work GREAT.
 
use ONLY the weight of the tool, and do it in 2-3 passes rather than pressing hard, and in 1 pass.
 
The Dremel with a cutting wheel works well for aluminum but for steel, you'd definitely be better off with a jig saw or similar.

Arcygenical is right - forcing the tool will slow you down and increase the rate at which the cutting wheels wear out.
 
Or, go for the gusto, and get a 4" or 4.5" grinder, and some cutting wheels!! Yeah!!! :rolleyes:

I found myself using the thicker wheels more often, since they were less likely to break if you fed them in a little fast. Make certain you're wearing good eye protection too!!! I can't stress that enough, especially when one of those wheels breaks off and whizzes a sharp hot piece of cutting wheel right past your head!!! :eek:
 
Yeah I was wearing goggle for sure!

Well, the project is finished, and it came out NICE. I came out of it with a couple burns, some new tools, and a lighter wallet. I think I burned up the rotary tool that I just bought (Craftsman 2.0 amp one) so I am going to take it back tomorrow and have them fix/replace it. I went to Harbor Freight today and bought a 3" air grinder, and it got the job done quick! I cut more metal today than I did yesterday and I only used one wheel, and there was still plenty of "meat" left on it! For $25 it got the job done.

I will be posting up some pics tomorrow or so. Thanks for all the input.
 
Wasn't there a tutorial or thread about "What to use a Dremel for and what not to use?" Something like that, but yeah it is not a good to for cutting steel, not big stuff. When I cut I whip out my autobody tools and use my air cutoff tool or plasma (brothers).
 
Do they have a air-powered dremel? One that works of a compressor. Thatd be nice, it probably could pack a lot of power.
 
I dont know if they have one that is that small, but I picked up one that uses 3" wheels, it made short work of the case.
 
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