The only un aswered Question.

[hmorgoth]

I have never seen this question answered before.
So How do all you case modders cut those dead straight window holes and fan holes in yur cases.
I have tryed a lodes of ways but still get frustratied at teh end when it aint straight.

So please somebody tell me what i am diong wrong.
as my trusty dremel and hak sam just dont cut it.

[WebMasta33]

Ok... You can either...

1.) Just jig/dremel it out, and then file/sand it with either a file/rasp/sandpaper until it's nice and smooth.

2.) For fans, get a hole saw, perfect cut every time. They make them up and past 120mm.

3.) Use a guide for a dremel, like thier mini router attachment. Then setup a wood plank to run the dremel against, this will give you a near perfect cut.

I'm sure there are other ways, but those are the ones I know of.

[Joe]

There is one more, its a metal punch you use with a ratchet. They are big steel Die's you place one on eather side, with a hole in the center for a bolt. with a big ratchet, you tighten them together. One side is a sharp round blade the other is just a base. as you crank them together one side punches though the case side making a perfect, no bur, hole.

they are expensive, like 100$ die's. they are made for punching holes in sheet metal.

[WebMasta33]

Originally posted by Joe:

they are expensive, like 100$ die's. they are made for punching holes in sheet metal.

$100 bucks???! That's probably why I've never heard of it (I read about cheap mods)

Sheesh... Next thing ya know, somone will post about how a $49,000 precision laser can cut lines 1/512 of an inch wide and up to 1/64232 of an inch in precision.

[Butcher]

holesaws are cheap and effective, that or get handy with a file

[grep]

a tool called a fly cutter, basically its a lathe tool thats mounted on a bar. the bar is adjustable its used like a drill bit, but in a very heavy drill press or better yet in a vertical milling machine. the lathe tool scribes a circle and cuts its way thru the work piece making a very precise hole. The tool Joe described is called a knock out punch. Yes there quite expensive and there manufactured by Greenlee. Standard sizes only go up to 2 1/2", I just bought a set and it was $120. I use them all the time in my work. There used by electricians to make the holes for conduit.
Hole saws work, but unless you use a drill press its hard to keep them from wobbling and cutting an imperfect hole. Even a drill press sometimes is not good enough to keep the hole saw from wobbling. When the sawblade just starts to break thru the work piece its got a high chance of jamming, make damm sure the work is really clamped down tight, else your going to have a big piece of sheet metal whipping around like a giant knife blade. This is not good even if you have fully paid medical insurance.

Grep

[clone]

whell if you send me the case i can have some one put it up an laser cnc machine but you have to write the cam program for him
j/k just busting you he wouldnt stop production for a computer case

[Brad]

all of the big stores use laser cutters, or something similar.

For our purposes, it doesn't matter too much, as you will be using plastic molding around the edge of the window, which will cover up anything out to a couple of mm.

[WebMasta33]

Originally posted by Brad
as you will be using plastic molding around the edge of the window, which will cover up anything out to a couple of mm.

Ya know... Not to crap that or anything. But I truely hate that molding. I prefer the "cut hole, sand cut to a perfect edge, then rivit or epoxy the plexi on". I really think the molding is getting to be overdone, and it looks tacky.

*plink* *plink* <-- My two cents.

[Brad]

yeah I know, I think without the molding looks better too, but with the molding is a bit easier

[Lonely Raven]

I too am of the anti-molding crowd.

I think web masta pretty much spelled it out for you.

Here is my current setup for holes and windows.

------------------------------------------------------------------------------------

Used Dewalt (corded) drill from a used tool store $20

Bi-Metal 114mm hole saw from major hardware store $24

Bi-Metal 80mm hole saw from major hardware store $8

New, low end "Skill" brand Jig saw and 6 fine tooth blades $40

I cut pretty damn straight windows (no molding) by hand, but
I have years of experience cutting things other then my fingers.
For a couple of bux more you can get two "C" clamps and a steel
ruler and use that as a guide for cutting straight lines, and use
the LARGE hole saw for cutting out the curves/corners in the
windows. IE mark out the corners and drill 4 holes with the
hole saw, then line up the edges of the holes with the ruler and
cut straight lines with the jig saw. I'm sorry I don't have pictures
of the procedure, but I hope you get what I'm saying.

Then a few bux for the sand paper, or if you have a dremel,
just take down the rough edges and your fine. I have yet to
need a file for any of my case cutting. This all works equally
well with plastic as well as metal. You just have to watch the
melt factor with plastic.

[clone]

i just use cnc water jet to cut holes that way the plex and the cut match PERFET first try

[beav]

Thanks clone, but not everyone has access to a water jet.

I use a jigsaw, and it works wonders...just a little fixit job with a file and some sandpaper afterwards gives me near perfect windows. However, for fan holes, i use a hole saw. Luckily, i have a drill press. I don't see how people use a hole saw with a regular hand drill.

2 large C clamps are essential for clamping down your object. Also, stick a block of wood or something under neath the cutting area.