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View Full Version : Best tool to make clean cuts in side panels?



MisterChief
05-17-2005, 12:14 PM
Good morning.

I am curious as to how I should cut the panel of my case (installing a window). Recently, I experimented with a freehand grinding/cutting wheel, but the end result was sloppy and unappealing. Hacksaws have also proven to be cumbersome. I'm sure this has been asked before, so if you could direct me to a thread or site with further information, it would be greatly appreciated.:)

Thanks in advance,
MC

Crimson Sky
05-17-2005, 12:53 PM
Hi MC and welcome to TBCS--I've found that a good jigsaw and fine metal blade (say 18TPI, or teeth per-inch) works really well for intricate cuts as well as simple openings. Many people also like Dremel and rotary tools fitted with cut-off wheels, but I find this to be pure butchery sometimes. Here area few pics of what level of detail can be cut into a side panel with a jigsaw, some good planning and patience:

http://www.thebestcasescenario.com/images/photoalbum/16/fc-finishing_17.jpg

http://www.thebestcasescenario.com/images/photoalbum/16/fc_window_finished_.jpg

http://www.thebestcasescenario.com/images/photoalbum/16/fc-window_33.jpg

Don't be discouraged by the intricacy of that Far Cry window, I'm just trying to show that even big tools like a jigsaw can make fine cuts in side panels. remember that even scraggly cuts can be cleaned with hand files and sandpaper ;) I really have to pimp my book here because it contains a complete guide to cutting that window with a jigsaw. MaximumPC Guide to Extreme PC Mods (http://www.amazon.com/exec/obidos/tg/detail/-/0789731924/ref=ase_thebestcase06-20/104-2293833-4935913?v=glance&s=books) Great stuff in there for the beginner and expert!

/shamlessplug

MisterChief
05-17-2005, 06:47 PM
Thanks a lot CS. I will definatley check out your book (being a subscriber to MaximumPC and all... :) ). I now see that a dremel tool is a modders best friend, as well as model builders. I'm beginning to see that my model building skill will come in quite handy!

Thanks again, and best of luck in your current and future projects!

MC

Xato
05-17-2005, 09:59 PM
i <3 my jigsaw

I never got around to buying a dremel, i havent really needed one yet.

nil8
05-18-2005, 12:58 PM
I found using a hacksaw blade by hand, a nibbling tool or a dremel are all good options, but they take time and practice to get right.

I've never seen anyone use a jigsaw blade for case modding before, I will have to try that out on my next project.

JesDer
05-18-2005, 02:27 PM
I am curious as to how I should cut the panel of my case (installing a window).

Just a simple window .. Jigsaw is the best bet (as most here will tell you). The methods used to get fine detail will vary greatly depending on what level of detail you need and who you talk to :)

Personally I like using Dremels for most things. They are by far the most usefull tool for general hobbies. The picture below was cut into some sheet steel using mainly a Dremel and jeweler's saw for the extra fine details. The extremely small lines were all cut using a dremel with micro drill bits on a drillpress attachment. Then finished with a jeweler's saw. I would say only about 15% of this was not done with a dremel.

http://www.jesder.com/pics/dragon26tmp.jpg

Malatory
05-18-2005, 03:16 PM
Jigsaw would be great for a simple widow (at least with my skill level with it). Simple window would be a square or oval window in the side of the case.

now I did this with the cutoff disk on a drimel (WARNING not as nice a CrimsomSkys)

http://dragonfly.bodybydk.com/drgnfly_final2.jpg

MisterChief
05-18-2005, 06:06 PM
Thanks a lot for the tips, guys!

nil8
05-26-2005, 01:34 PM
I got the book about 5 days ago and it's already taught me things I didn't know and I've done 2 case mods already. Good book, cheap, pick it up. It won't tell you exactly how to turn a wheelchair into a computer, but it will cover the basics of what you have to do and how you have to do it.

My best experience with a clean cut window is a nibbler, but I have to warn you it takes a long, long, long, long time and your hands get tired fairly fast using one. It does make clean square cuts. Corners are a little trickier, but still easier than freehand.