Basic case modding...

[Lord09]

Hello all,

I couldn't really find anything, so I apologize if this questions been asked before. I just installed my water cooling kit, the temperatures are great, unfortunately I have an oversized radiator that's too big to mount inside the case.

What I'm trying to do is to cut out the top of my case to accomdate the radiator and 2 120mm fans side by side, kind of like a huge blow hole I suppose.

I also liked to cut about 3 circles about an inch of so in diamater to route hoses and my power cord for my pump. Also what are those rubber inserts called that bad the metal edges called?

Thats pretty much all I want to do. Unfortunately I have no idea what to buy. What would be the bare minimum I need to complete his project? Also part recommednations and places to order would be appreciated as well. I don't want to skimp on quality, but the lower the $$$, the better. I don't really plan to do much with these tools after I'm done with them.

Or better yet, any kind person in SoCal wanna help me out? :)

DP

[Skiing Squirrel]

Probably a hole-saw for the 1 inch holes, and the rubber stuff is called, I think, automotive trim.

[RadiationMan]

You might be able to find some rubber grommets(I think that's what they're called) that will line the holes and protect your hoses and cords from the sharp edges. I would check out the hardware store to see what they have before cutting any holes. A 1" hole saw might be able to be picked up at a hardware store for $10. If you have a dremel, and you want to go cheap, you could drill a bunch of holes in a circle, and clean up the edges with a grinding stone on the dremel. A lot of work, but if you dont want to spend the $10 for a hole saw, and you got a dremel it could be done. I'd probably just buy the hole saw. It's easier, and would probably look better.

To cut the top for your radiator/fans: If you are cutting fairly straight cuts, a jigsaw and a metal cutting blade works well, and doesn't take much time. If the cuts are more curved, I would probably use a dremel. You can cover the raw edges with door edge guards found at any autostore.

If you are going to do any modding now, you probably will do more in the future. If you don't already have a Dremel, or some other rotary tool, I recommend to get one. You can get them at any hardware store, and even walmart(evil). It is probably one of the most useful modding tools you could own.

I don't know how much knowledge you have. If I told you stuff you already know, I'm sorry. Hope this helps.

[Lord09]

No, don't be sorry at all. Your post was very informative and I have very little knowledge at all about case modding.

Yeah, it looks like I'm going to break down and get a dremel. With that dremel do you think I'll be able to do everything? I looked at some kits at Fry's for $80, they all come with a ton of attachments. I was hoping to spend less, but if that's the going rate, I don't mind. Any specific brands to look for?

Whats the best method to cut perfect circles? What would I need in addition ( if at all ) to the dremel?

Thanks again...

[Ktulu]

I think hole saw=perfect cirlce

btw- i was wondering that exact thinglord09, tks for posting it for me :)

[RadiationMan]

Sorry I haven't posted in a few days. I've been out of town, away from my computer.

I have just a basic single speed Dremel and it works well. (I recieved it as a gift) If I were to go buy one, I would get one with a variable speed. Variable speed is good for cutting plastics. If you cut it at too high of a speed, it will just melt and throw molten plastic everywhere and not cut well. I just made a variable speed controller with an outlet box, an outlet, a dimmer switch, and an appliance cord for about $15.

As far as attachments, the only ones I have used for modding was found in the cutting and sanding kit, assorted cutting wheels and a small sanding drum. But I think if you buy the kit with everything, it's cheaper than buying it separately. I have also bought a grinding stone to help grind material away faster. Dremel is the only brand that I have used, and I like it fine. They have an excellent assortment of attachments, bits, cutting wheels, etc. I have also heard very good things about the Black and Decker brand rotary tools, though I have no experience with them. I would check to see what attachments you can get for the Black and Decker and if the Dremel attachments fit on them. I don't know. Maybe someone who has used it, could post and give you their opinion.

A hole saw does make the best circles, and they work fast, though they can bind sometimes. Personally, I would use a hole saw for holes up to 80mm, and a Dremel for holes bigger than 80mm and irregular cuts. You can use the scroll saw for longer, generally straight cuts, that would take forever to cut with the Dremel, or you can use the Dremel if you've got time.

If you have any more questions, or I didn't explain something fully, please ask. These are just my personal opinions, and others may have differing and better ideas.

Hope this helps.

edit* Another accessory I would definitely get is safety glasses.
Check this (http://forum.oc-forums.com/vb/showthread.php?s=&threadid=209077) thread out. ;)

Also, be sure to put masking tape all over the surface you are cutting to keep from scratching your pretty paint job.

[Lord09]

Thanks for the info. I'm probably gonna buy a Dremel branded dremel soon. Should I buy a corded one? They're fairly expensive, so I was wondering how good the battery ones are, since they're cheaper.

Also, with just a dremel, whats the best "method" to cur circles and straight cuts? Also, whats the best wheel to use for cutting metal?

Thanks all,

DP

[RadiationMan]

A cordless one would be cool. Very handy not having a cord tethering you down or pulling on the tool at an inopportune moment. I wonder though, if the corded one would have more power and turning force. I have a cordless drill, and it works well, but runs out of juice after just a short time of screwing deck screws. Then I have to wait 2 to 3 hours to let it charge back up. My corded drill has much more power and works as long as I have it plugged in, but I have to drag the cord around. I'm guessing (without any actual experience), the cordless dremel may not have as much power, and you would have to charge it regularly. If that doesn't bother you, the cordless one would be convenient to handle.

I saw the basic single speed corded Dremel at walmart(evil) tonight, including a few cutoff wheels, a sanding drum, and if I remember right, a couple of cutting bits for about $35. The high speed deluxe set with all the accessories for $59.95. The high speed variable speed Dremel with a few more accessories than the basic set and a flexshaft for $69.95. The $35 basic set is what I use, and it works fine. I don't use my homemade speed controller when I cut metal, only plastic.

When cutting with the rotary tool, take your time. Don't put a lot of pressure on the wheel, or put it in a bind, or the wheel will shatter and pieces will fly(eye protection).

I like the Heavy Duty wheels, and many like the fiber glass cutoff wheels. The Heavy Duty wheels last longer, but are more prone to shattering. The fiberglass wheels dont break as easy, but wear out quicker, and are kind of pricey. Stay away from the thin general purpose wheels, they break way too easy, and become frustrating.

[Lord09]

Ahhh, I see... Thanks for the information. I might stop by Walmart tonight then... $35 seems plenty reasonable.

Just one more question, what exactly is a hole saw? Do they attach to the dremel itself? Or is it a seperate tool?

Also, what would you use to make holes in a side panel for fan scews?

Also, I'm assuming that the higher the rpm, the more powerful the dremel is. I saw a one dremel that spun up 35K rpm and a cordless one that was adjustable for either 7.5 or 15K. What kinda power should I be looking for.

Thanks for the info and I read the post about your eye. I'm glad your feeling better, I'll definately invest in a pair.

DP

[RadiationMan]

Here (http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=41436) is a link that shows a hole saw. It attaches to a drill. To use it you need the hole saw and a mandrel. The mandrel is like a drill bit that keeps the hole saw centered while you are cutting. You can either buy a set like the one in the link or buy the hole saws individually according to the size you need. You should be able to get what you need at any hardware store. If you have a Harbor Freight store in your area, they have Chinese made, cheap quality tools, at very inexpensive prices. If it is a tool you are only going to use a few times, it's a good place to go.

If you are cutting plastic, a cheap carbon steel hole saw would be fine, just make sure the drill is turning in reverse so the blade doesn't bind. If you are cutting your metal case, you will need a bi-metal hole saw. They are more expensive, but will be able to get through the metal without dulling. When using the hole saw just use very small amount of pressure, and work slowly. If you go too fast, the saw will bind. Basically, just "scratch" through the material you are cutting.

As far as the holes for the fan screws, just use a drill. You can line the holes up first using a fan grill and a writing utensil of choice.

Let me know how it turns out and post some pics when you are finished.