Cutting your own side window

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Wish I'd have got photos for this, but I'll try and get one of the final result. It'll make you chuckle if nothing else. tl;dr version is "A couple of lessons learned about case modding".

Ok, so, I work in the IT department of a private school, and over the summer holiday I thought it'd be a bit of fun to make use of the DT workshop. Plan was to use the laser cutter to slice a nice even hole in the side panel of my el cheapo case (Can't list the brand as it's a competitor, but it rhymes with roverfleck). It's not a bad case for the price, the interior is all black with some coloured tool-less drive locking units and a bit of cable management.

I get down to the lab, and can't for the bloody life of me work out how to use the laser cutter. The panel I'm slicing up has a pair of fan grilles already, so I eye it up and start casting my eye over the lab's shelves for the dremel...

Fast forward an hour and a half, and I've got the bloody grille off with a nice big hole left in the side of my case. Instead of doing the logical thing and filing the rough edges down with a flat file, I swap the head on the dremel and try to file it down with that. Ooops. In addition to all this mess, I've managed to scratch the side panel. Repeatedly. With nice big, deep, lines.

I give up on trying to sort the sides of the hole out, and cut a piece of transparent blue perspex to size. Out comes the hot glue gun and in it goes. After it's "complete" I attach the blue cold cathodes and away I go :D

Fast forward a couple of days and I'm unhappy with the panel. Out comes the wet'n'dry and black spray paint, after having the foresight to stick masking tape over the perspex panel first. All goes swimmingly, the panel looks a bit more reasonable... and then I try to use silicon sealant to tidy up the edges of the hole. Dear, oh dear, oh dear, that was a mistake.
 
Next stage, I decide to work out this bloody laser cutter, to sort out the mess of silicon sealant smudges, rough metal edges and barely-perceptible scratches I figure that if I cut the hole bigger I can sort it all out in one fell swoop.

I finally figure out the damn thing, and get it burning a nice line along my panel. It doesn't cut all the way through on the first slice, but looking at the burn it seems that it would go through on the third or fourth line - each full round taking about an hour and a half. I keep an eye on it as far as the first 90 degree angle, and as the dimensions look about right I leave it to it and wander off to do some work.

45 minutes later, I come back to take a look at the progress... I've only gone and put the bloody height of the cut in incorrectly, and it's burnt up to about 3mm from the top of the panel - meaning that if it had cut all the way through, it would have taken out all of the underlying support for locking the panel into place. Starting to lose my rag with it a little, and to regret not actually planning the thing properly...

So, I clean up the silicon sealant as best I can, replace the badly smudged perspex panel, and spot something on the shelf to:
A) Give myself and others a warning and...
B) making it look actually not too bad (this on a relative scale of fricking awful to goddamn terrible)...

case1.jpg


...

case2.jpg
 
Thanks for putting me off modding my Antec 300

:D

Don't be put off, just make sure you plan it properly first. If you're using a laser cutter (especially one that won't cut in the first sweep), practice on the inside of the panel first. If going down the dremel route, use a flat metal file to clean the edges!
 
just make the window slightly bigger? then you would cut out the rough edges

find the four corners of your window drill some pilot holes big enough to fit a jigsaw blade through but keep holes inside of the window and cut four straight lines from one pilot hole to the other

use some strong double sided tape for your perspex or drill each corner and use four black self tapping screws
 
Well, the laser cutter was in all likelyhood a CO2 laser cutter so it would not have been able to cut the metal.

Could well be right, gotta admit I know absolutely nothing about them so your guess is as good as mine. I know it's supposedly capable of 20mm acrylic, but kinda irrelevent now anyway - given up on the damn thing!
 
Grumble grumble, ok I've sourced some carbon fibre vinyl wrap, and some proper pvc blowhole trim - will post pics when it's tidied up :D

I've also picked up some black self-wrapping cable braiding, to sort out those motherboard headers. Planning on a bit of a play with the cable management (such as it is) within the box - I've already done a lot of tidying inside but will nose around and see what I can do.
 
Could well be right, gotta admit I know absolutely nothing about them so your guess is as good as mine. I know it's supposedly capable of 20mm acrylic, but kinda irrelevent now anyway - given up on the damn thing!

Nah, mines better :p. Its unlikely (although not impossible) a school has a metalcutting laser (100K price tag or around that price). Its much more likely a universal, HPC or epilog laser.
 
Well, I know the thing's on lease - several grand a year. Might use it to etch something in the window, but I just know that'll end in disaster :p

The story progresses, however. Window trim showed up today, now just waiting for the vinyl which I got delivered to work. As I'm off this week it'll be next monday before I do any more tinkering!
 
Right, so, time for an update with a few pics - finally had time to tidy things up a bit :D

With the hazard tape removed. You can see what a mess the side panel became, between me, the dremel, the laser cutter, wet'n'dry, black spray paint and the dodgy silicon sealant stuff some pimply gimp in B'n'Q recommended.

case3.jpg



Window pushed out, carbon fibre vinyl wrap on, blowhole trim in place:

case4.jpg



Rear shot of the panel with the window and cold cathodes back in.

case5.jpg



Muuuuchhhh better :D

case6.jpg



Slightly better pic of the case fans and cathodes:

case7.jpg



And with the room lights off. Reasonably happy with this now, although I'll probably end up buying a decent, new case at the end of the month.

case8.jpg
 
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