Side panel mods

ChrisLandin · 3 Feb 2011 at 17:43

Does anybody know whats the best way to get nice clean long cuts when modding a side panel. Im sure somewhere I read about laser work but not to sure on that. Any ideas experience out there please?

Thekwango · 3 Feb 2011 at 20:08

when you say long clean cuts, is it a simple square/rectangular shape you are trying to cut into the case. if so a dremmel or similar with good quality reinforced cutting discs a few g-clamps and a striaght edge, along with a set of fine sanding discs should give a decent finish

Apem · 3 Feb 2011 at 20:12

I think make first cut with a dremel type tool then use a jigsaw would be the best bet.

Thekwango · 3 Feb 2011 at 20:23

Apem said:
I think make first cut with a dremel type tool then use a jigsaw would be the best bet.

if you were to use a jigsaw, it'd be best use a drill a to drill out a pilot first of all, make sure you use a very fine tooth blade on the jigsaw as to course a blade can sometimes leave quite a 'torn' appearance to the finished cut which makes smoothing it a much longer job.

I'd be interested to know what design you're looking to acheive?

i'm experimenting with getting this design onto a case panel for a friend...

Buchanan0204 · 3 Feb 2011 at 20:26

Thekwango said:
if you were to use a jigsaw, it'd be best use a drill a to drill out a pilot first of all, make sure you use a very fine tooth blade on the jigsaw as to course a blade can sometimes leave quite a 'torn' appearance to the finished cut which makes smoothing it a much longer job.

I'd be interested to know what design you're looking to acheive?

i'm experimenting with getting this design onto a case panel for a friend...

That just looks as though someone has plunged into the case panel with a serrated edge blade, then flipped it over.

ChrisLandin · 3 Feb 2011 at 20:34

My current 800d has taken a hammering from me over the last few months and ive just got a replacement side panel and I want to do the same work again but make it look very clean. Im not home just now but I will put up a pic when i get time of what i want it to look like. All my previous cuts ahve been with a jigsaw and im not the best with electrical power tools haha.

Thekwango · 3 Feb 2011 at 20:35

Buchanan0204 said:
That just looks as though someone has plunged into the case panel with a serrated edge blade, then flipped it over.

thats the effect thats wanted, the guy wants it too look like something has ripped its way out from inside the case. its actually proving harder to do than you'd think. i've vandalised a few old case panels trying it out!!

they were actually inspired by this.....

a poster for the movie wolverine i believe, i suppose it'd be slightly better than the generic side panels that are out there, and probably quite unique. least it will be once i've had my dremmel to it

PhillyDee · 3 Feb 2011 at 20:42

Leave it to professional cutting companies! You will never ever get it as straight as a company that uses milling machines, wire cutters or laser cutters.

Find a local sub con company that has EDM machining such as wire cutting, plasma or laser cutting. Even waterjet cutting would suffice. I love the finish that is left by wire cutting!

Thekwango · 3 Feb 2011 at 20:57

PhillyDee said:
Leave it to professional cutting companies! You will never ever get it as straight as a company that uses milling machines, wire cutters or laser cutters.

Find a local sub con company that has EDM machining such as wire cutting, plasma or laser cutting. Even waterjet cutting would suffice. I love the finish that is left by wire cutting!

that is very very true, but where's the fun in that

think of the pleasure gained from cutting your case panel too shreds!!

Buchanan0204 · 3 Feb 2011 at 21:15

I'd imagine it would be quite scraggly and easy to cut yourself on, how do you plan on tidying it up and take the edge off? Must be quite difficult with thin metal.

Thekwango · 3 Feb 2011 at 22:36

Buchanan0204 said:
I'd imagine it would be quite scraggly and easy to cut yourself on, how do you plan on tidying it up and take the edge off? Must be quite difficult with thin metal.

thats the problem i'm having. replicating the torn metal look is very easy. to try and avoid him opening a vein i've been trying to round the edges with a fine hand file, and also curl the edges back slightly but i'm finding the thin metal breaking and folding almost at right angles rather than rounding back.

the best results i've actually had were with a 10 year old 'tiny' pc case panel, but that was because it has a suprisingly thick case panel, about twice as thick as the more modern panels i've been trying out.

in truth i've quite easily gotten the main sort of effect he wanted but as said it's a damn death trap!! and taking the case panel on or off could result in a trip to A&E!! been trying to source some sort of clear acrylic glue that could be painted over the the edges to take the actual sharpness off but not impair the actual look

ChrisLandin · 3 Feb 2011 at 22:39

PhillyDee said:
Leave it to professional cutting companies! You will never ever get it as straight as a company that uses milling machines, wire cutters or laser cutters.

Find a local sub con company that has EDM machining such as wire cutting, plasma or laser cutting. Even waterjet cutting would suffice. I love the finish that is left by wire cutting!

Nice one. Cheers Philly. Thats what I will do mate. Thanks for the tip

Thekwango · 3 Feb 2011 at 22:43

ChrisLandin said:
Nice one. Cheers Philly. Thats what I will do mate. Thanks for the tip

what is you are trying to achieve? if its simply a square/rectangular hole as i was saying before, you could very easily and cheaply do it yourself, and use some edge trim to make it look nice and tidy