Update time kids. I was looking critically at the case and I wasn't at all happy with the appearance if I wanted to put a window in the side panel, the whole thing just didn't look right.
So I thought to hell with it, and started hacking away with the jigsaw, drill and handsaw and removed even more metal. I removed the front grill/ 80mm fans mounting assembly in total, fixed the grill to the reverse side of the front panel using araldite which seems to have gone perfectly (I'll post a pic when its hardened overnight as I don't want to disturb it). I also took considerably more out of the two upright side panels and slotted each one so a 120mm fan could be installed where the two 80mm would normally go. Obviously the intake draw from this fan is not gonna be as high as normal due to the restricted opening in the front panel, but it doesn't have to be as theres the floor mounted 120mm fan drawing in also with a full size opening. Theres also gonna be a large "dead spot" in the center of the fan due it's the motor, but I reckon it "might" work, I suppose it depends on the fan speed, the higher the speed the more air but I don't want to compromise on noise so lets see how it goes.
I also had to reinforce the lower mountings of both forward uprights now as I've lost two rivet mountings per side, so I knocked a small right angled bracket for each side, riveted them in place and now theres no movement at all. There is, however a bit of flex in the uprights as there areas where theres only a 2mm strip now ('cos I removed so much) but I'm hoping when the fan is mounted, it'll goes rigid again and if not I'll see about strengthening these two areas., Anyways, heres a coupla pics.
I've also got some edge trim coming soon so I can tidy up the edges a lot and I've got some fine modelling filler already to repair any cosmetic damage prior to spraying the internals.