I've predrilled from the start. I used non-tapered screws, I even tried clamping the piece with a wooden vice to prevent splitting. Except fro the 2 'beams' nothing has split. The problem with the beams is they are only 1/2 by 1 1/4 profile. Theres just not enough material to hold.
When I run the blower(at 5V) in the open I can only here the sound of air rushing around, there isn't the hum like normal fans. The rear section will be covered in some sound dampening material(most likely carpet). There shouldn't be much noise coming from the front but I may do the black felt thing again since I like the way it looks in my old case. Overall I'm hoping for near silence, if possible I may try to lower the voltage on the blower below 5V.
Well I'm done for the day. I finished the MB and IO panel.
I used an older MB this time. The IO panel and MB went together alot easier than I expected. I still have to connect the MB tray to the case. Most likely I'll glue it when everything else has been completed. I tossed in a few wires to show how they will run out of the back of the case.