How to cut a window into aluminum?

flexyjerkov · 10 Mar 2010 at 09:39

It's my first time attempting to cut into an aluminum side panel.

Have just brought myself a Lian Li PC-A70FB and want to minimalise the chance of screw ups. It's a basic rectangle window shape with curved edges and the perspex window will sit behind it as it's already been etched onto.

How would one go about cutting a window safely with minimal screw ups and to give it that professional look

?

the wopster · 10 Mar 2010 at 13:03

lots of masking tape,dremmel,correct mesurments,time and a very steady hand.
just make sure you mesure up propeley and take your time dont rush it or you will make a hash of it

pastymuncher · 10 Mar 2010 at 13:23

A jigsaw would be better than a Dremel for cutting a window.

Orangey · 10 Mar 2010 at 13:40

pastymuncher said:
A jigsaw would be better than a Dremel for cutting a window.

+1

If you use a Dremel you will need a low speed setting and patience, also a facemask might be a good idea. And a file to finish off the edges.

Da[]San · 10 Mar 2010 at 14:04

Definatley use a Jigsaw with a metal saw.
Fix the panel to a proper work bench with some strong clamps and check that it will not move, the last thing you wan't to do is to cut your fingers off..eeek.

the wopster · 10 Mar 2010 at 17:07

thats probz how i buggerd mine up by using a dremmel and not taking my time

Kanifee · 10 Mar 2010 at 18:10

The way i did mine was mask the area you do not want to cut, make sure you mesure twice cut once. take your time and use a very good fine tooth metal blade for your jigsaw, make sure you have a few so that you can change the blade regular, it is good to keep a sharp blade in because the cuts will stay clean, if possible use a piece of smooth wood, clamp it in place as a guide and leave your self atleast 1mm to your desired line, that way you can file it back and sand the edge to finish it.

Heres mine on my lian li A05b

C64 · 10 Mar 2010 at 18:56

take it to a place that can cut it for you with pro tools shouldn't cost too much

3t3P · 10 Mar 2010 at 19:00

kanifee that looks like a laser did those cuts! awesome
how did you get such round corners?

Kanifee · 10 Mar 2010 at 21:41

Files and sandpaper and lots of time, lots of mesuring as well, make sure you are 100% confidant you can pull it off before you start or it will end in tears lol!

Makhaira · 10 Mar 2010 at 21:50

Rubber edging is your friend if you make a mistake, so don't panic if you have issues! There are actually some positives to using edging, like ease of replacing the window if you want to try something different or it gets damaged.

gary996 · 11 Mar 2010 at 16:09

Had mine done on a flow jet

Danm54 · 11 Mar 2010 at 21:30

Kanifee thats a real neat job you've done there, id be well proud

D.Roberts · 12 Mar 2010 at 14:09

flexyjerkov said:
It's my first time attempting to cut into an aluminum side panel.

Have just brought myself a Lian Li PC-A70FB and want to minimalise the chance of screw ups. It's a basic rectangle window shape with curved edges and the perspex window will sit behind it as it's already been etched onto.

How would one go about cutting a window safely with minimal screw ups and to give it that professional look ?

where you live i could help if you are local.