What dremel for case modding?

I used a Dremel 3000 to cut out a window out of 2mm thick aluminium, I went through about 3 very cheap discs and it took about 2 hours (the window was about 40cm x 40cm).
 
I bought the lowest model, with carbon fibre cutting discs, dremel branded.

I practiced on an old computer case to get the lines straight and work out the most precise way to hold the tool.

After a couple hours of practice i then moved to the real one. I did it in 20 minute bursts, taking a short break each time till i was done.

Then onto the filing to make sure the edges are smooth.

Then put the rubber trim around the edge and tape in the perspex :)
 
I bought the lowest model, with carbon fibre cutting discs, dremel branded.

I practiced on an old computer case to get the lines straight and work out the most precise way to hold the tool.

After a couple hours of practice i then moved to the real one. I did it in 20 minute bursts, taking a short break each time till i was done.

Then onto the filing to make sure the edges are smooth.

Then put the rubber trim around the edge and tape in the perspex :)

Pretty much my plan, I've got an old case to test it out on :)

Got some rubber edging and more acrylic than I'll ever need :p
 
Cheers for the info kd


For anyone else looking to mod their case I'll post up my results of the dremel 3000 in my build log :)

Link in sig.
 
I would have thought for a long line cut a Jig Saw would be the preferred option. I would probably start the cut with the dremel to get a wide enough slot for the jig saw blade and off i would go. Maybe use the dremel for finer points of cut.
 
I use a 3000 when I'm doing fiddly bits. Dremel actually sell multiple thickness of cutting disc. I found the thicker ones don't shatter, but obviously are a lot thicker than the thinner ones.

However I have started to use a plunge router for cutting windows. If you take your time setting up you get a great, clean, straight cut. For 1mm sheet I do use a sacrificial sheet of mdf.
 
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