Well this is my first post after weeks on weeks of looking around reading and getting a feel for what PC moding is about.. But I have not seen or looked over any articles reguarding techniques for best dremel results. I am refering to Advanced (curved)Window (lexan/plexi) cutting, Panel cutting and getting those nice curves, and other things such as blow holes. I am new to Case Moding and I am baically looking for some Dremel tips/tricks for getting good results. I bought a Dremel MultiPro Model 395 (5,000 - 35,000 rpm) and some reinforced cutting discs (model 426 I think) as I have read that is the standard for most modders. If anyone can give me a few tips/tricks, warnings, or general advice it would be great. Thanks in advance...

When cutting plastic, make sure you cut it and don't melt it. If you melt it your Dremel is spinning too fast, slow it down a hair using the controls built into the more expensive models or (heh, heh) with your AC variac.

Curves are hard with the cutting discs, no matter what anyone else says. I might not be the Dremel champion of some on these forums, but I still say slow and methodical is the way to go. Just take your time and slowly go over the curves. It's okay if you make some small mistakes (you can always erase them with the sanding discs).

Use engraving bits to engrave your own window. To hell with the "appliques".

For curves, you will need to get as close to the line as you can with small straight cuts and then grind out the remainder with a metal sanding/grinding bit.

When you are cutting long straights, save the small diameter (worn out) cutting disks...so your straights on the curves can be shorter.

Something to check out if you want to wait. Dremel is having a case mod contest with the winners case posted as their featured project on the website. May have alot of good info once the contest ends and the winner is chosen. Check it out here

I will keep those in mind.. alot of very good info there (to beat all from some of the guys I idolize as case modders) and yes I would say there will be a good write up on case mod technique after that contest.. I hope to see someone from the board win but at any rate I will hope to be able to post pics of my case soon.. It wont be the prettiest thing I am sure.. I dont even like the case as its kinda oogly but it will be a good learning case as I would not want to go hacking on a Lian Li or Antek lol... Thanks and anymore suggestions would be awesome

first some saftey tips, make sure you wear eye protection, those flying disks can hurt and i can imagine what they would do to your eye. And trust me you are going to have a few break off.

Second either work in a well ventalated space or were some respitory protection, that the metal dust is not good for you lungs( i was coughing for 2 days after the first case ).


As for technique, your on the right track, cutting disk 426(fiberglass reinforced) is good for cutting, getting anything less just results in more shrapnel. Take your time with any cut, make small cuts, no more that 1/2 inch at a time, and double check your line.

Just mod it twizted. You will learn more from actually doing your mod than you could from reading hundreds of articles. If you are happy with the results, phuck what anybody else thinks.

Already planning on trip tomorrow to go get material but I hope I get some replies on my other post about suggestions first

I was looking and somewhere I seen something about masking the whole backside of the door panel and cutting from the inside ? Whats the tape for.. I also was messing around last night and found an old Lite-on CD-Rom that was burnt up and put a square window in the top of it just to experiment. Forgive the poor cut but it was the first time I used a Dremel let alone try to cut a straight line. The hole was big and the metal is reasonably thick. I ended up useing a whole disk and then some doing it do I dunno if I did something wrong or right lol. Anyway I am trying

Oh yeah and I forgot.. What is the best bit for DeBurring I have the thing that came with the Dremel kit. Its like a yellow/gold stone.. It worked on the CD-Rom above ok but it was a bit destructive lol... Name or model number of the proper attachment would be kool.. thanks..

You could use what you have. There are a re number of other abrasive stones and wheels to choose from. Check out the #500 wheel when your picking up your supplies. Maybe even a #502 & 503 flap wheel and sanding dums for the finish work.
Remember to take EVERYTHING out of the case before you start. One stray picece of material is all it will take to short something out.

Welcome to the world of the dremel. I own three. I don't have three hands, heck I don't even have three sets of all the bits, but I have three new dremel tools. They are leet.

you want to learn how to get good with a dremel? Go get a piece of screp metal. Get a wariable curve protractor and draw a few curves on it and cut them out. Within a few mins you'll be a 733t dremeling mod hippie like myself.

My favorite technique is a three step phase called " Ruger's three step phase" Acctually there's a lot of steps, but most of them involve artificial stimulants (caffine) and loud music, so i'll jump straight to the actual three steps of cutting.

Pre steps-

measure

put on safety goggles

drink another beverage

cover lip of said beverage (mouthful of dust tastes bad)

measure again

Step 1- Use the large reinforced cutting wheel to induce pain and suffering on your subject... NO! I mean use the cutting wheel to cut out a rought line INSIDE by about .5mm of your drawn line.

Step two- Get the mini sandpaper bit for your dremel. It looks like a tiny tamborine but is rolled in a think cardboad sandpaper that's rough. Use this to get a good circle and go right up to your line. It makes a lot of dust but works WELL

Step three. Get the polishing kit and buy the little green polishing stones bits. They are a soft clay stone and do a GREAT job for finishing. They are used qucickly but they are the best. Use them to finish the cut and smooth to a great shine.

Post steps-

ALWAYS ALWAYS ALWAYS use a damp cloth and remove ALL metal shavings from your case. this step should take nearly an hour if you do it right. NEVER leave the shavings behind.

Consume the rest of your beverage.




Ok ant to know something cool? Your steel case metal CAN be polished to a mirror state using a dremel tool, sandpaper, water and sweat. <-you don't use the sweat you mostly lose a lot of it


I took the Power supply bracket off the back of my antec 1030 SX.

First I took a steel wire brush and took the finish off down to the bare metal.

Next I got the dremel and took the brass wire bit and polished it up a BIT.

Next I wet sanded for three hours using 5 different grits of sandpaper.

By this time it was near mirror finish.

Finally I took the plastic brush tip on the dremel and polishing compound and polished. Then I buffed with dremel. Then I fell asleep sitting up.

What do the cutting wheels look like? I managed to find a dremal that had been gathering dust in our basement, but any and all documentation has been lost. Because of that, and a lack of dremel experiance, I don't know what I'm looking for.

This is the recommended cutting bit in my opnition.


Number 426, fiberglass reinforced cutting wheel, anything less is just going to end up as shrapnel in the wall. Recommend that you at lease get 20 or so of these, when cutting metel these should last you at least a foot or so(depending on the case). Think i saw a 20 pack of these at sears for like 7 buck, could be wrong though

I have five of these. They feel brittle.

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those will work, but they look to be the regular disc, which are going to last about 1/2 the time as the reinforced disc and will break about 3 times as much, you can use them, but i would recommend buying the reinfoced disks as well

I'm going to see if I can pick up any reinforced bits while I'm out this weekend. I'm also going to have to hunt down some safety glasses. I know I have some here.

Saftey Glasses are defintly required!!!, Those flying disks are dangerous when they break, if you dont where them you probably will need one of these:

I understand completely.