I am a certified n00b at case modding. I recently killed my old AMD k6-2 300 computer. Instead of buying one pre-built I decided to build one. It turned out well. However I used a pre-mod case. In order to prove to myself that I could do it myself I found a case from our old computer [lightning strike fried the mobo last summer] and then I just started to think about what I could do to it. I have already painted the inside of it gloss red; the outside will be gloss black.

Now for my question.

I want to cut two windows in the case; one on the side, and one on the top. What is the best way to do this. I have been grinding away at it with my Dremel tool and cutting wheel, but it's ust not working out. The batteries wear down very quickly. Any help will be appreciated.

im doing my window tomorow but based on what ive read and heard, you should just keep wearing the material down, until the dremel breaks through.

If its aluminum you could use a nibbler but I wouldnt advise it with steel as your hand will hate you for it.

I cut my windows with a jig saw and then smooth them out with files. Then I hit it with some sandpaper.

Quote: Originally Posted by eclipse3346 ...my Dremel tool and cutting wheel, but it's ust not working out. The batteries wear down very quickly. Any help will be appreciated.

what the hell are u doing with a battery powered dremel in the first place!

Yeah... Battery-powered dremel isn't gonna get you far. If you're serious about getting into case modding, you should probably get a corded one. A jigsaw is a good choice as well, but a dremel--as much as I hate those damn things--is way more versatile. But, if you think it's gonna be a one-time enterprise (you're gonna do this one case and that's it), save yourself the expense and get a nibbler. They are below $10. True, cutting a window with it IS gonna hurt (and I should know), but you know--no pain no gain. You won't be able to use your hand for a week once you're done, but the satisfaction...

Use a layer or two of masking tape on the surface you plan to cut to protect the surface/paint. It also gives you a good surface to draw your cut lines on as well.

A Dremel will cut it fine with some patience and a steady hand.
Sadly though, the rechargable models are pretty lame compared to a corded Dremel. Yours should get the job done though, It will just take a little longer.
Try to let the Dremel do most of the work, rather then applying gorilla pressure trying to get thru the material.

You could also opt for a jigsaw as suggested, but make sure to mask it like above, and back your panel with some scrap plywood to prevent warping your workpiece.

Both options will most likely leave you with some clean up work to be done with files and some sandpaper to refine your edges.

On the nibbler, do yourself a favor and throw it at the cat that keeps getting in the trash cans.

[Edit] Also take your time and try not to heat the piece up too much while cutting. This will help keep your new paint job from becoming a melted, bubbled up mess.

JIGSAW ALL THE WAY

i was cutting my friends antec (steel) case with a dremel, and we were doing a 4 sided window. it took like half an hour to cut one side with the dremel, then we switched to jigsaw and finished it off in 20 min. those things are awesome. 1 note tho, dremel is better if you want to keep your paintjob and for details.

Dremel, anyone who thinks a jigsaw is better should look at my Short Circuit mod, cut with a jigsaw, and Storm Warning, cut with a dremel.

Anyone who thinks the jigsaw is better is going to the sixth layer of hell in a handbasket alongside the shower-wankers and Jihad terrorists.

Quote: Originally Posted by j-dogg Anyone who thinks the jigsaw is better is going to the sixth layer of hell in a handbasket alongside the shower-wankers and Jihad terrorists.

thats the idea.

if you want to cut ur case then i suggest using a black dremel blade and of a starter hole just drill a hole in it i've cut holes with my dremel and only had to change the blade only once

now for jigsaws not even worth touching with a ten foot pole

The reasn for the battery powered Dremel is that I am borrowing it from a friend. I cant seem to find my other one.. lost in the garage...

so explain to me why the jigsaw is so much worse. ive used the dremel, and yes it does do cleaner cuts, but if you sand it all down(i use a spindle sander sometime, it gets it so smooth), why wouldnt it be good?

Those slamming a jigsaw for cutting a window were probably using a wood blade to cut the metal panel Get a METAL CUTTING BLADE for your jigsaw, and use a backing piece like jinx suggested and you will NEVER do large cuts with a Dremel again.

BTW, KayinStorm & I use the same battery powered Dremel. I've cut blowholes with it and DAMN it takes a LOOOOOOONG time. Jigsaw: faster, better, smarter.

I only use a cordless for engraving acrylic-5,000 RPM does it without burning the acrylic. I have a corded Dremel, but in aluminum, a nibbler is king.