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Jigsaw to cut a window?

J

Jbroad572

Limp Gawd
Joined
Jan 23, 2004
Messages
192
Is a jigsaw cool to cut windows with? It may have a few curves in it here and there, still not sure. I have a friend who is letting me borrow his jigsaw and dremel tool. They all have wood bits though, so I will need to purchase my own.. What bits and pieces do I need to pick up to cut my V1000? I've got to cut a big rectangle out the top of the case, which I will use the jig for and I guess smooth it down with the dremel and the same for the window, if you guys recommend it.
 
I've cut a few windows and blowholes, and yeah, the jigsaw is the way to go. It pretty much eats through aluminum easily, and is almost as efficient on steel. I've tried using a dremel and honestly, unless you have superdetailed work, stick with the jigsaw and just use the dremel to smooth stuff out once you're done.
 
Jigsaw is the way to go. Use a fine toothed metal cutting blade.
Use masking tape and tape over the entire outside of the panel, because it's smooth and you won't have to work around the bends and latching lugs). The tape will prevent any scratches to the finish.
Mark your cut on the masking tape. Drill a hole near the mark and start your cut there.

Make sure you have the panel clamped down firmly (so it doesn't vibrate and jump around), makes for a smoother cut.

Take your time!!!, do not rush the job. If you do it right, all you will have to do is go around it a lightly with a file to finish it up for a clean edge. No need for power tools for that part of the job.
 
Sarge said:
Jigsaw is the way to go. Use a fine toothed metal cutting blade.
Use masking tape and tape over the entire outside of the panel, because it's smooth and you won't have to work around the bends and latching lugs). The tape will prevent any scratches to the finish.
Mark your cut on the masking tape. Drill a hole near the mark and start your cut there.

Make sure you have the panel clamped down firmly (so it doesn't vibrate and jump around), makes for a smoother cut.

Take your time!!!, do not rush the job. If you do it right, all you will have to do is go around it a lightly with a file to finish it up for a clean edge. No need for power tools for that part of the job.
Click to expand...

This is pretty much the way to do it. Just to re-itterate, buy a blade designed to cut metal, additionally you might want to try using the jigsaw on a scrap piece of metal (if you have one lying about) to get a feel of how the tool works. Those who aren't accustomed to the jittery up and down movement could have problems. (but the same is for any power tool, understanding how it feels under normal operation and how to control it is essential.)
 
Ditto on the last two posts.

Use a 24 tpi (teeth per inch) blade in the jigsaw - you can get one at Home Depot.

To clean the cut, filing the edge works much better than a Dremel. File at a *tangent* to flatten the edge then make a pass or two with the file at a 45º angle to "round" it. Cleans and smooths it up. Molding can hide imperfections.....
 
Ok, thanks fellas. I won't need 2 of those blades, similar to how you need to have multiple cutting discs with a dremel right?
So, the rounded corners and any curves shouldn't be a problem if I just take my time, that was my biggest concern.
Thanks again for all the help.
 
Make sure to clamp down the metal good when you cut. The jigsaw can throw that metal around real good, and it'll screw up your nice cut.
 
And make sure you tape everything so the foot of the jigsaw doesn't leave huge gashes accross your work
 
Ok, thanks fellas. I won't need 2 of those blades, similar to how you need to have multiple cutting discs with a dremel right?
Click to expand...
If you do anything that requires you to need a second blade, then most likely your modding project is already a total failure. Cumputer cases are pretty light work for a jigsaw.
Another thing. If you can, remove the panel to be cut, from the case. If possible, have the flat surface of the panel laying flat on a piece of plywood, to minimize vibration. Have as much of the panel supported as possble, including areas which are yet to be cut, or have already been cut. Just turn the panel as necessary to complete the cut.
If you are very careful and take your time, the cut will be clean enough that you won't need any moulding to cover imperfections.
Good luck and post some pics!
 
Dammit, just cleaned up the wires. Now, I got to take everything back out. I could have just waited, argh! Oh well, I'm guessing this will become a practice (removing and installing) :p
 
Jigsaw is the only way to do large scare metal cutting. Make sure to use a fine tooth blade and GO SLOWLY. Also mask the entire panel with masking tape. The small metal particles will easily scratch anything that it touches.
 
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