Cutting a side-window.

Scryus · 16 May 2012 at 22:34

Hey guys.

I thought this would be the most applicable place to ask this question, I'm thinking of modding a side-window into a case in the near future, and I am currently tool-less. What would I need to get to ensure that I can actually cut the metal, for starters?

I've heard the word "dremel" thrown about casually, but would all of them be capable of cutting such a material? Asking my step-dad, he doesn't believe he possesses any tools that would allow the cutting of metal in this fashion.

Ideally I want to spend as little as possible, but get a quality tool - everyone's dream, I guess. Any ideas? Recommendations? Cheers.

Scryus.

OptimaLnrg · 16 May 2012 at 22:38

yea you'll need a rotary dremel thingy and a steady hand.

Then you'll need plexi for the window. To stick it to the metal you could use double sided foam tape, I use that for lots of things in the pc. But be warned, it sticks hard!

To cover the cut you'll need something like a u-channel molding.

King Damager · 17 May 2012 at 00:15

Dremel. Absolutely Dremel.

Don't get the cheap alternatives either, I know that the Dremel is much better at handling heat than the alternatives, and even that gets hot.

The Dremel 300-30 with a set of cutting discs would probably set you back about £40-50, and that was after a quick google, I'm sure if you shopped around you could find it better.

You don't have to need some kind of u-channel molding for the cut. Just get a file and file the cut to a nice smooth point

kd

Scryus · 18 May 2012 at 02:10

Thanks for the replies. I have some u-channel already, time to check out the 300-30.

bremen1874 · 18 May 2012 at 02:21

Or just use a jigsaw fitted with a suitable blade. Apply masking tape the panel first to avoid scratches.

shadowscotland · 18 May 2012 at 10:02

I used dremel reinforced cutting disks but with a standard power drill.
Not so easy to handle due to it's size and weight - but works fine.

As bremen said above - jigsaw works a treat - use a new sharp blade and take it slow and steady idealy with lots of clamps and a workbench
A hack saw also works perfectly well - or a Padsaw
Or if you have a Stanley knife - you can get a metal saw attachement for about £4
'Stanley Saw Knife Blades for Metal 1275MB'

All saws will need a starter hole if making a window

charlaph · 19 May 2012 at 18:23

Is your case panel steel or aluminium? I tried cutting a window in an old Antec with a dremel. I got through about 6 of the reinforced cutting discs before giving up and taking an angle grinder with a cutting disc to it, then used the dremel to deburr it. The Dremel will work, but on steel any thicker than a sheet of tissue paper it'll take some time.

Mutt · 20 May 2012 at 01:45

I hope the OP doesn't mind me asking my own question here.

I've got access to a jigsaw but I'm not sure which blades to use for cutting a window in my steel Shinobi side panel. Could someone who's used a jigsaw to mod a side panel tell me exactly which blades they used?

Cheers fella's.

_______________

Update:

After a fair bit of research I decided on these blades:

Hopefully they'll do the job. A bargain as well. £3 inc delivery for a 5-pack.