FT03 Side Panel Slice and Dice

[sonsonate]

Hello People. I want to cut some holes into the FT03 side panels, but I need a bit of help. What I want to do is cut a hole on the FT03 on the sides for the video card(s) and HDDs to breathe since the aluminum seems to reflect the heat and keep them hot. (43c side panel off vs 50+C with panel on)

I have a Dremel tool and I'd like to know what wheel to use for cutting. Would the Dremel SM510c work okay? I have some experience with a jigsaw and metal cutting -- would that be better? Any recommendations for a company to cut it in NYC?

Also, I'm trying to find some material to make a grill -- something fine, but easy to clean like a fine metal mesh. How do you case modders attach grills to the inside of the case? Bolt it on? Glue it down? Screw it in?

The plexiglass seems easy enough to deal with, but any recommendations for cutting, handling or atttaching would be helpful.

Thanks for the help.

 

[DoubleTap]

How thick are those panels?

I bet you could find a local shop to water cut your holes for not very much money - that's what I would do.

 

[CMadki4]

Honestly the fanciest cutting wheel I've ever used it just one of these. And I've done a crap ton of modding on steel and aluminum cases. Done right you won't even know it was done by hand.

I did this just recently on my SZ68R5. It's aluminum. And I used an aluminum hex modders mesh I picked up from FrozenCPU.

To attach the mesh, the cleanest looking way is with a 2 part clear epoxy. Just a few dabs of it in the corners and intermittently along the edges and it will hold on for ages. No holes or rivets to interrupt your nice factory finished look.

 

[sonsonate]

@Doubletap

Yeahhhhh, it would be really easy to go that route, but probably a bit of cash. Also, I'm the type of person (well, along with my girlfriend) that likes to try the DIY route. I'll call and ask for a quote anyway. Thanks!

@cmadki4

Dude, thanks a lot for the info. One last question: the rounded corners, lol. Is that by hand with the dremel and then the edged cleaned with a file? We're wondering how you got that done so cleanly.

 

[CMadki4]

@Doubletap

Yeahhhhh, it would be really easy to go that route, but probably a bit of cash. Also, I'm the type of person (well, along with my girlfriend) that likes to try the DIY route. I'll call and ask for a quote anyway. Thanks!

@cmadki4

Dude, thanks a lot for the info. One last question: the rounded corners, lol. Is that by hand with the dremel and then the edged cleaned with a file? We're wondering how you got that done so cleanly.

Absolutely DIY for the win. If you were getting something elaborate like the Intel skull or ROG logo, then I would say go for pro.

For the rounded corners, I just traced something round that was about the right radius. The one in the picture above is traced off the back end of one of those super fat sharpie markers.

I cut just up to the fillet (rounded edge/corner), then cut little diagonal cuts until the piece is free. See here BEFORE the corners are cleaned up.

Then I grind away the rest with a little mill tool (see pic above) on the dremel. And further clean it up with a sanding drum. A super fine file is great for cleaning up the edges. Like those little needle file sets you can get for just a few bucks.

Also, as you see above, mask your entire panel. I do this because it protects the whole thing while I'm handling it. Protects the finish. Mark your layout on it. And when you start cutting, it gives you a little protection from the moments the dremel jumps out of the cut and onto where you don't want it to.