Okay I am looking at new case because....well, I like how it looks and am growing tired of carrying around my Stacker after 6 months of use......I found a Lian Li, and well its deeper than the Stacker, I know Stacker the most amazing case I have ever owned, but its soooo damn heavy....so any way my question

Is there any way to cut a "perfect" square for a window in side panel?

Here is the case...

http://www.performance-pcs.com/catalog/ind...roducts_id=3529

Without the modified window the case is $169, as much as a stacker, with the window its $229 and I dont really like the window being outside the case, hence my desire to cut the window myself....

I dont plan on drilling holes for the window, I figure a good adhesive would work for attaching the Lexan or or whatever material I decide to use as a window....

Measure twice, cut once. You'll get a straighter cut if you use a jigsaw. Leave a little bit conservative, and file it clean when you're done.

You'll need a Dremel, some 30w motor oil, and a dispenser bottle for the oil. Mask or mark of the area you plan on cutting. Then simply begin cutting with the Dremel, lubricating with plenty of oil. Don't cut directly on your line, leave a little edge. When your done cutting, clean up the oil and go back over the edge with the sanding attachment. You should end up with a smooth, clean edge. Remeber to take your time for best results.

Okay, thanks, what about nibblers?....Any one ever use those?

I don't think you want to use a nibbler for the entire window, they're a pain to use and you'll have mad blisters on your hands by the time you're done.

Yeah but it seems like it might be more accurate as far as cutting goes.....I guess I will just need to steady my hands....

You can use a jig saw and a straightedge to get a better cut if you're not comfortable following the pencil line.. dremel will always be a little harder, but it's possible to do a really nice job.

Why not practise on an old case or piece of something?

nibblers "rip" alum. more than cut. I would not use a nibbler for a window mod, alot of room for mistake and its not a tool for fine cutting or straight.




Great tip, I plan to cut a window in the case I am modding now.

Yeah thats what I plan on doing, I have cut a lot of holes....done a lot of drilling but Ive never done anything in the ways of cutting aluminum, at the company I work for I just have a piece of aluminum sent through a laser cutter....sadly enough I cant send my side panel through it.....its against company policy, but, I can use every other tool in the shop..damn company policies....

Either way I will take your suggestion practice, and see how it goes...I just want it too look very nice, you know like a factory job...

The best thing would probably be an ESAB plasma cutter. My father has one, prices are astronomical on them though so not practical.

Make sure to cut the hole "smaller" so you have room to correct mistakes and to sand down. I just did some cutting of some low grade steel with a Dremel and was amazed at the ease. GL !

Yeah I have done some small cutting with my Dremel on my current case and I am a little weary of slipping and scratching the hell out of my case, I might just use a saber saw....

use a hole saw or large drill bit for the corners cause there the hardest part i use a 1"-1 1/2" hole saw for it then just join them up with the jigsaw allways mask off and clamp the work dowm the entire length of the cut or the vibration/up down movement of the blade will bent the job

Yhea I know how!!!! You need to make a oversived jig which is a template offset enough to accomodate the base of the jigsaw less a 32nd " clean to the line with a mill file very carefully and then with some sand paper too smooth the file marks for a nice finish. But heres the tricky part you need someone that has a woodworking shop with a band saw and router table with flush trim bits preferably with the bearing on the bottom Its going to be a drawn out process if you truly want it accurate and precise!!! If you call me I would explain exactly how to go about it but to be honest with you I would say get the windowed side panel and drill the rivots and put the glass on the other side and re rivet it! Dude seriously I have been a wood worker for 20 years and have worked all fields in the industry makeing a presise gig is alot of work and I am sure that it is more than you wish to endevour especialy if it isnt used for mor than one thing in multitudes that is!!!! Spend the coin and do as I suggested with drilling the rivots you will thank me. Oh and incidently I have the Silverstone tjo6 case and it has the glass on the exterior it really isnt that big of a deal I like it fine do what I said if you dont like it. Hope I could help but if you are persistant on doing it I will give you my # considering that I make 18th &19th century period furniture reproductions exclusively by hand I think I am qualified to know the deffinition of precise and accurate! Let me know if I can help.

Yhea I know how!!!! You need to make a oversived jig which is a template offset enough to accomodate the base of the jigsaw less a 32nd " clean to the line with a mill file very carefully and then with some sand paper too smooth the file marks for a nice finish. But heres the tricky part you need someone that has a woodworking shop with a band saw and router table with flush trim bits preferably with the bearing on the bottom Its going to be a drawn out process if you truly want it accurate and precise if you call me I would explain exactly how to go about it but to be honest with you I would sat drill the rivots and put the glass on the other side and re rivet it! Dude seriously I have been a wood worker for 20 years and have worked all fields in the industry makeing a presise gig is alot of work and I am sure that it is more than you wish to endevour especialy if it isnt used for mor than one thing in multitudes that is!!!! Spend the coin and do as I suggested with drilling the rivots you will thank me.

Hmmm... Now that I think about it, 10w motor oil might be better for the job since its not as heavy. 30w seems like overkill for a Dremel and aluminum job. Either one should work fine though.

I use WD-40, works fine for me. Then again I always take twice as long, barely putting pressure on the wheel, nothing is more annoying than changing cutting wheels when doing a job that big.

You probably decided against the nibbler, from what I have read, but I figured I'd post this anyways;

I have used a nibbler for a side panel window before:
Came out a little rough:


Looks alright once the moulding was installed:


It's not worth the pain, using a nibbler, and takes forever.

Btw, I bought that window kit from FrozenCPU.com and it sucks. It takes forever just to get the window mounted the right way and it's too flimsy. The window pops out if you aren't careful with it. Eventually, after it popping out like 3 or 4 times that window met my fist, shattered it and threw into the garbage. I am never that rough or violent, just to give you an idea how much it sucked.