Help smoothing side pannel

[Sleepy_Steve]

So, I finally got arround to modding my full tower (project link in sig) for dual 120mm intakes up front. While I was at it, I moved the potential 3x80mm intakes that were on the front over to the motherboard side just in front of the mobo tray.

The Good: To help out airflow, I drilled out the vent holes that were already in the side of the case to a larger diameter... all 200-300 of them or so. This worked as I think I doubled the open area leading to those fans. (just need to make some filters now)

The Bad: The holes were a bit rough as I had drilled from the inside of the panel I think (hard to remember as progress has been that slow). I then got the bright idea to countersink EVERY hole to make them flush / smooth. This might have worked if the side panel was made of wood, or if the counter sink had been for metal (as I suspect it might not have been designed for this.

The Question: Now the side of my case feels about like a cheese grater to the touch. Does anyone have any ideas on how I can fix this / make my side panel smooth again before repainting the case?

[Captain Slug]

A power brush bit on a power drill will help deburr and polish the panel prior to painting. I tend to prefer them over orbital sanders.
http://www.mcmaster.com/param/images/powerbrushes/brushtype_flatend.gif
http://www.mcmaster.com/param/images/powerbrushes/brushtype_wheel.gif

[Sleepy_Steve]

Hmm, I don't think those cause enough damage to fix this, its a bit past deburring at the moment. But if I come across any of those I'll try and give it a shot at the expense of the paint.

I've basically made a little crater rim on each hole. Do you know if they make counter sink bits specifically for metal that might be able to just give the holes a once over and smooth things out?

[thideras]

Hmm, I don't think those cause enough damage to fix this, its a bit past deburring at the moment. But if I come across any of those I'll try and give it a shot at the expense of the paint.

I've basically made a little crater rim on each hole. Do you know if they make counter sink bits specifically for metal that might be able to just give the holes a once over and smooth things out?Can you post pictures of what this looks like? I'm having a hard time following...

[Sleepy_Steve]

Well, I can try taking something with my phone, but I had to give my nice camera back to its rightful owner (my dad), so IF i can manage to post a picture, it wont be high quality at all.

I'll post up in a few minutes weather or not it worked.

[Sleepy_Steve]

Yeah, it seems that I can only send the picture to other phones.

I've gotta figure out how to unlock the ability to DL stuff to my computer... And I also cant seem to find a mini USB cable to just plug the thing in to see what happens :)

[turkey4550]

Hey mate, you know anyone who works on cars for a living? If not run by a automotive shop. All you need to do is run a die grinder over it with a 3m roloc disc on it. I was an auto technician long before a computer geek, and I use mine all of the time. The average grinder spins at 10,000 rpm, when mated with the roloc disc which is basicalled like a coated scotch brite pad, there will be nothing but baby butt smooth metal afterwards. Just run by a shop and offer one of tech's like $5 to do it for you.