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Dremel + cutting Case = Bad (Need Help)

A

amdownzintel

Limp Gawd
Joined
Oct 24, 2004
Messages
201
Ok so I bought a Dremel XRP 400 . I got the one with the box that came with a few attachments and drill bits and things like that. My question is that well I was cutting my stacker case (to mount a 3 X 120mm Radiator) and well first I used the drill bill to cut a hole in the case and that went fine. Then when I try to actually go forward and cut the case well
that's where a lot of noise and not a lot of movement starts to take place. I just tried using a cutting wheel which was provided and well within just 1 min. the wheel managed to snap in half and fly across the room. So my question is to you what do I do? Is there a certain bit out there that will do this a whole lot easier? Or should I just go buy a jig saw? Please respond quickly so then I can go to the store before they close. Thank You
 
Time to alter some metal. Working on the inside of the line running the tool at max (or high) speed start making your line. The object here is to start making a groove. If you try to cut the metal through on the first pass, you will go through about 57 cutting disks unless you break some too, then the number could be higher. If you think of what you are doing as sanding in a precise spot you will achieve success. You are letting the speed of the tool do the work, not the sharpness of the disk. Let your ears and eyes be your guide and if you hear the tool slow down in pitch or observe the tool starting to oscillate, back off.
Click to expand...

http://www.bit-tech.net/article/101/1

^^ Check that out buddy
 
Thats a good tutorial. I also recommend taping on and around the area you are dremmeling with masking tape or painter's tape. It will protect your case from scratches/gouges if you accidently zing the dremmel across the surface when you get kickback from a burr or something.

Another alternative is to use a hole saw type thing attached to a drill. Lots of people swear by that to cut holes for fans. I just used a dremmel not to long ago to cut an 80mm fan hole, and it went pretty easy. Didn't even break a disk.

The key to not breaking the disk is to not use the very highest settings to dremmel at. Maybe 3/4 speed is what I use. Also, hold the dremmel very firm to avoid the kickback if you get stuck for a milisecond where it throws the dremmel off course. Just go lightly around your circle/square/etc until you keep getting deeper and deeper. Then make the final pass a little harder to cut it out. Then grind, polish, etc..
 
Steel is a motherfucker to get through with a Dremel, but sometimes it's the only thing to use depending on what you're cutting out. If it's a circle > a drill press will save u tons of frustration. If it's a design, keep it very very simple.
 
if you are willing to take the time a nibbler tool will make nice cuts provided that you are patient and dont mind a sore hand afterwards, plus you dont have to worry about scratches or gouges
 
Alright well out of frustration I went down to Sears and bought a Jig Saw. Boy did that make it go so much easier. The only bad thing that happened is I don't think I can hear anymore :( Damn is that thing loud. The hole is all pretty much done, just going to wait until tomorrow to finish up the rest of it because it's getting kind of late and don't want neighbors complaining and such. I definately think I was going way too fast though for the cutting wheel and just expected it to go right through the thing. Thanks for all the suggestions and well this is my first major mod and I think it went half way decent I guess.
 
post some pics of your mod when u are done! Good Luck and Enjoy
 
You might want to invest in a hole saw. Clean circular cuts. Cutting circles with a jigsaw/dremel can be done, but it's more of a pain.
 
amdownzintel said:
Ok so I bought a Dremel XRP 400 . I got the one with the box that came with a few attachments and drill bits and things like that. My question is that well I was cutting my stacker case (to mount a 3 X 120mm Radiator) and well first I used the drill bill to cut a hole in the case and that went fine. Then when I try to actually go forward and cut the case well
that's where a lot of noise and not a lot of movement starts to take place. I just tried using a cutting wheel which was provided and well within just 1 min. the wheel managed to snap in half and fly across the room. So my question is to you what do I do? Is there a certain bit out there that will do this a whole lot easier? Or should I just go buy a jig saw? Please respond quickly so then I can go to the store before they close. Thank You
Click to expand...
1] - very likely you were not using a reinforced cutting disk. Those will not break near as easily. They look like this :
tools.2.jpg


2] - you were likely using the cutting disk in a way that it was not intended = lateral force. Contrary to what some believe, those disks are made for straight cuts only.

3] - since the Dremel has no real torque to speak of, you have to rely on high RPM's to do the job.

The Dremel really is a handy tool. And an inexpensive way for beginners to start cutting. The problem is that people tend to expect too much from them. The Dremel is OK for smaller jobs, but becomes woefully inadequate once the scale of the job increases.
 
yea i tried cutting a window out of my old case with a dremel and it did not work so well. for now on, i am going to be using either one of the mills or C&C machines at my dads shop.
 
CletisMckloskey47 said:
yea i tried cutting a window out of my old case with a dremel and it did not work so well. for now on, i am going to be using either one of the mills or C&C machines at my dads shop.
Click to expand...
That will do it! :cool: .... It's "CNC" by the way ... = "Computer Numerically Controlled".

If you have access to an air compressor you could use a die grinder with cut-off disks to do your window. That is what I do - along with carbide rotary files. Those cut through steel like butter. Easy to get nice lines that way.

Here are a couple images of my last window project if you're interested :

pic1 ~ pic2 ~ pic3 ~ pic4
 
that's weird, i'm modding a case myself and i also bought a dremel to make the work easy.
i've cutted 2x80 mm holes in it with my dremel without any bigger problems, you just have to practise a bit more ^^
 
will a dremel be able to cut through brushed aluminum?
would the nibbler be a better option for tight corners
Is the metal going to be too thick for either?
Will the brushed aluminum chip or flake?

(as in this silverstone htpc case case?)

I would like to cut out two 5.25" holes where the stealthed drives would go.
 
jazzyfromco said:
will a dremel be able to cut through brushed aluminum?
would the nibbler be a better option for tight corners
Is the metal going to be too thick for either?
Will the brushed aluminum chip or flake?

(as in this silverstone htpc case case?)

I would like to cut out two 5.25" holes where the stealthed drives would go.
Click to expand...
1 - yes, it slices thru brushed aluminum like butter (almost, hehe)
2 - for tight corners, yes. Or, use a combo of both nibbler + dremel. (use small diameter cutting disk for better tight turn cuts on a dremel)
3 - dremel will cut thru nearly anything, nibbler will be a bit tougher to use on thick metal
4 - i've never had it flake before


I just got done cutting my radiator hole on my LL V1000. Its essentially 2x120mm. The V1000 is brushed aluminum i guess, and looks exactly like the metal in that silverstone case. I took my time and printed out a template, then sliced thru it no problem with a dremel cutting disk.

edit: Since you want to cut out those 5.25'' bays, you will definetly want to practice a few times on some spare metal of the same quality. For cutting out the bays, the dremel would work great, just take your time and do it right. Tape everything off really good. Cutting on an open showing face will have to be absolutely straight so it looks nice. Initially cut it with a cutting disk as straight as you can, then grind it to remove burrs or rough edges, then use a sanding bit to smooth it all out. Getting the edges perfectly straight will be a little tough if you haven't dremelled before. I recommend making a 5.25'' template, then cutting your hole a little bit smaller to start with. Test fit, then grind out more if you need it bigger.
 
Any gauge metal found on a case will be able to be cut with a Dremel. You just have to have a couple reinforced cutting wheels handy and be gentle while cutting or you'll snap them like nothing.
 
^^^ - agreed.

Re: brushed aluminum .... the finish is part of the material & will not "chip or flake".
 
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