is this supposed to happen?

[Blackearth]

i recently bought a dremel to finally do my window mod and a couple of other things. i probably should have searched out some sort of guide or something but anyway. . .my cutting wheels are grinding away like water. i've gone throught all the heavy duty (3 or 4 i think) wheels that came with it and a 5 pack of reinforced wheels and i'm not even finished with the top half of my case (full tower). is it all in the angle? it seemed to cut really well sometimes but as i moved onto a curve or just a slight change in angle the wheel would kind of catch and just start grinding away into nothing. is it normal to go through a large amoun of disks? if so how many can i expect? would a jigsaw be any easier or better to use? i hope this comes out good . . .

[*JEREMY*]

yeah it takes alot,the reinforced ones last longer though.The method i use is drill a hole and then take a pair of tin snips and cut out the hole leaving about 1/8" from your line and then take one of the drum sanders for the dremel and finish.It comes out perfect that way.You could even use the jigsaw instead of tin snips but you have to lay your case side on a piece of styrofoam or something to keep it from bending or maybe off the edge of a table

[-=HN=- Wild9]

just use tinsnips to cut holes, but use a drill to make a starter hole, and make sure you get some sheet metal to practice with the tinsnips on, when you get good with the tinsnips you wont leave a jagged edge on the hole you cut.

[typhoonmike]

Do not force your Dremel. It's a high speed low torque machine. The reason it cuts is because of the incredible speed. Those cutting wheels are fragile. The reinforced ones last longer but they can still break. Dremels are slow and not really meant for what you are doing but if that's all you have then it works. You have to etch your pattern. Make small cuts and just keeping going over it until it is finished.

[IFMU]

tin snips? where are you guys gettin these tin snips?! The metal on all the cases Ive had are way to thick to even try it on... I mean my god 1 of 2 things would come outta that if I tried to use tin snips... another visit to the doc due to carpal tunnel kicken in or the snips would snap... Ive used the dremel to cut the case even for fans holes... granted it is far from easy but it is doable... The biggest pain is that it is SLOW going... Just take it slow... The first window I cut I went through several wheels... but the next one I slowed down alot and ended cuttin a much larger hole with a lot less wheels...

[Über~PhLuBB]

I used a jigsaw to cut mine. I set the panel on two cinderblocks, with a towel on the bricks.

Check out the result here:
http://forums.overclockers.ws/vb/showthread.php?s=&threadid=29083

It's near the bottom of the very last page.

[foxmulder]

I'd use a jigsaw/w metal blade. It's fast, precise, and cheap. If you have a dremel you can use it for small areas, tight corners and such.

[dolemitecomputer]

I just started modding also with a dremel and I went through a lot of cutting wheels. I used the small thin ones that came with the dremel. The thing about a jigsaw is that it has a lot more kickback (from what I'm told) and the case or whatever would need to be clamped down. The dremel worked for me quite well except I have to send it in for a replacement :D

[Intraveinous]

Jigsaw all the way baby... My recommendation is to tape down newspaper with painters wide masking tape, that way you don't scrape up the paint on your case with the jigsaw. Go slow and make sure you use a good sharp metal cutting blade. I like the Bosch Progressors. Anyway, be careful, wear eye, hand and ear protection, go slow, clamp it to some styrofoam if you can get it and have fun!
Peace
John

[Über~PhLuBB]

Originally posted by dolemitecomputer
I just started modding also with a dremel and I went through a lot of cutting wheels. I used the small thin ones that came with the dremel. The thing about a jigsaw is that it has a lot more kickback (from what I'm told) and the case or whatever would need to be clamped down. The dremel worked for me quite well except I have to send it in for a replacement :D

There is a terrible ammount of vibration, but it's nothing your other hand (and if you happen to have 2 more hands handy in the form of a friend) can't take care of. You just hold it as close to the cut without losing any digits.

[Blackearth]

thanks for all the input guys. . .i think i just might try the jigsaw method. it seems like it would be easier since i do have some curves in my design plan. i've already got a jigsaw, but i probably need a different blade. i'm not too worried about scratching up the panel anymore, i was planning to paint it something eventually but now i'm going to have to (a couple slips w/ the dremel left some nasty marks, ). anybody have any ideas on what i should paint? should i do a simple design or paint it all one color?

[Oni]

I used an industrial strength air powered die grinder. Took me all of 15 minutes to get a nice, professional-looking hole.

[BK]

has anyone ever used a plasmacutter to mod there case, if so how did it work? good? bad?

[Boomerang]

I've tried a plasma cutter. I encountered a couple o problems. 1) It scorches the paint bad. If you don't mind, or are intending to re-paint, this is fine. 2) Unless you have a computer controlled plasma cutter handy, or have an INCREDIBLY steady hand, you will end up making cuts with fairly rough edges. These can be ground out with a dremel tool or whatever to smooth out the roughness. Basically, it can be done, but it'll take come cleaning up when our done.

HTH
Stephen

[IFMU]

The biggest detail about plasma cutters is that the material that you will be cutting needs to be CLEAN, no paint no dirt, grease (oil from fingers) absolutely clean from everything you can possibly remove and then some of what you cant too... But if you remove all the paint from a case then cut it a plasma cutter would work beautifully... Its the nature of the game with them cutters...