Cutting up cases

[Rx_Matador]

Well i was thinking about getting a PC-A05NB and modding in a window and a top 120x2 fan hole, but before i do had some questions on modding.
1. What are your favorite tools for cutting panels on cases?
2. Other tools i might need when doing this project.
3. Will a Dremel do just fine or do i need a specific wattage and rpm on the Dremel?
4. Tools you would normally use to fine tune your cuts. (files, ruler, tape measure, Etc...)
5. Is there anything thats going to be very difficult about this and would you discourage me from doing this for any reason.
And i forgot
6. Is there any guides you would recommend looking at before doing this.

 

[Rx_Matador]

Wow entirely wrong section can a mod please change this to cases & case modding sorry about that.

 

[aviduser]

I use a quality jigsaw to cut anything in my case. Put two layers of painters tape, layout your cut. If anything cut a little shy of your mark, then take a file to clean it up.

 

[WhiteFireDragon]

a dremel is the only power tool i own, and it works great for just about anything, including case modding. very versatile piece of equipment

 

[Rx_Matador]

a dremel is the only power tool i own, and it works great for just about anything, including case modding. very versatile piece of equipment

How long would it take to cut the stuff i want to with a dremel wouldnt it be a time consuming process.

 

[Shadowssong]

Practice on junk. Measure 3 times, cut once.

 

[hotbrass]

For fans, a hole saw does wonders. For windows I prefer to make the major cuts with a jigsaw and follow up with a dremel and metal file to clean it up.

 

[Ricedaddy]

My favorite tool for making cuts is a roto-zip. I definately prefer it to a dremel, but they are pricey if you don't have other uses for it. I second the idea of using a holesaw for fan cuts. I use a dremel and a file to clean up. Also, a previous poster was right about using scrap to practice. It will do wonders when you know what kind of resistence you are dealing with.

 

[Rx_Matador]

For fans, a hole saw does wonders. For windows I prefer to make the major cuts with a jigsaw and follow up with a dremel and metal file to clean it up.

when using a hole saw for fans what size piece would i use for a 120mm fan and what type of hole saw would you recommend for aluminum? Also for Dremels what size cutting wheel would you recommend and any specific type?

 

[hotbrass]

You should be able to get a 120mm hole saw at Lowe's or Home Depot. Just look on the package and it should tell you what it's rated for (wood, soft metal, etc.). For the Dremel I typically get the reinforced cutting discs.

http://www.mnpctech.com/DremelDisc.html

The regular cut off wheels tend to wear down too quickly. I really like the tungsten carbide bits as well. They have several different styles, but I've always had luck with this one.

http://www.amazon.com/Dremel-9901-Tungsten-Carbide-Cutter/dp/B00004UDJJ

If you crank your Dremel up to 35,000 rpm, that bit goes through the metal like it's nothing, especially aluminum. Just be careful it doesn't get away from you. I typically use the sanding/grinding bits to help smooth out the cut as well and then use a fine metal file to get it super smooth. Finish it off with some U-channel from mnpctech and you've got yourself a nice looking hole.