As for the rad set up, link in my sig for mine. I managed to fit a sr-1 480 and rx240 in the bottom but it is a very tight fit and has messed my psu position up. If you run with the 480 with the inlet/outlet at the front of the case then I am pretty sure you can get your psu in the correct place.
Tooling wise, I also used that dremel on my tj07 (though without the flex hose bit) and it is ok, not briliant but ok. As for the sanding / polishing - maybe I am not experienced enough with a dremel but I still prefered to do the last bit of filing by hand.
I think i'll certainly get a slim rad if I do get another one.
What spraypaints did you use? I certainly no longer have the budget for powdercoating as I'm saving for 3D
I'll also be doing quite a bit of filing by hand
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