Aluminium Cases

[simon275]

For the first time in many years I have a mod on the drawing board. Part of the mod involves putting a custom window on the side of the case. I am after a case with Aluminum side panels that would be easy cut. Many computer cases are made from cold rolled steel. Which I understand is hard to cut. Either you will chew through many many dremel cut off wheels or you need an angle grinder. While Aluminum you can take a Jigsaw to and is much easier to work.

Does this all sound correct? If yes then what Aluminium Cases are there out there?

[Zeroignite]

Steel is much harder to cut through then aluminum, but not impossible. This is being posted from a 0.8mm thick box with a sizeable window cut in. I think I went thorough about 6 heavy duty cutoff wheels, and it took maybe 2 hours, but I got it done.

In either case, be absolutely sure to wear eye protection. Dremelling metal sheet sends out a sandblast of metaldust, not to mention that a shattering cutoff wheel flies at a bit faster than the speed of sound ;). Oh, and with steel, the dust is hot enough to incandesce.

[mtekk]

To add to what Zeroignite said, if you are using a dremal cuttoff disk wear a breathing mask. It's more for the grinding disk dust than anything. I cut a hole for a 120MM fan in my steel case and used about 5 cuttoff disks on it. It should not have taken so many, but I kept slipping causing the disks to instantly shatter :dead:.

[Aviduser]

Cutting through steel side panels isn't all that hard.

http://www.hardwarecanucks.com/forum/gallery/14909-antec-300-window-mod.html

Theres a thread on when I cut a panel into my 300.


All you need is a roll of masking tape, a jigsaw and a few files. I think mnpctech.com has a video to doing it. Its best to use a high tpi (teeth per inch) blade on a higher speed, from my experience.



Though I have wanted an aluminum case so I could use a router to cut out a side window.

[SXRguyinMA]

my Monster project is a steel case, took a good 2 hours and 7 or 8 HD cut-off discs to get the "M" cut out, but it was worth it :up:

[crazybillybob]

All the early Cases that I moded in the past were steel. I just used my trusty jigsaw and cut through with no problem. I fact it's some times easier to cut ten aluminum. See soft aluminum likes to gum up the fine jigsaw blades which means you have to replace let more often. With a good quality jigsaw blade I could cut several intricate steel side panels.... the secret take your time.

No matter what your case is made of if your going to use a jigsaw cover the whole side in 3 or 4 layers of tape, This will keep you from scratching it up with the saw base.

I only use the Dremel to clean up the cut I made with the jig saw, and to finish the tight corners that I just couldn't get into with the jigsaw....

Best thing I did was get a couple of old cases and just go at it, figured out speeds and limitations to the cuts I could make.
Also keep the case supported close the the blade (with in a inch or two), this will help limit the amount the panel can flex when the jigsaw makes a stroke...helps keep the panel from deforming as you cut it!

Good luck!
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