Looks Nice!
KilJaeden said
You might notice that it is not all that clean. I will work on that a lot tomarrow. It did buckle a little. I think that it would have probably been better to use the dremel instead. Well it was the first time that I used a jigsaw and worked with metal. I am going to straighten up the edges with a dremel. I am also going to use window molding when I am finnished, so it will look a little better.
KilJaeden said
I want to mount the window using the same method in the picture below. I want it to be held in with screws like the one in the picture. Does anyone know of where I can get the screws needed to do this?
Looks like you're off to a great start!
When cutting thin sheet metal it sometimes help to lay it on a thin piece of scrap plywood. 1/4" or 3/8" works well. When you cut the case, just cut the wood along with it. It helps to clamp the sheet metal (in this instance the side of the case) to the wood. I know you've already cut this one, but once you get the modding bug you'll probably want to do another. (And another, and another, and...)
mmonnin's suggestion is great. Any decent hardware store should have a variety of fasteners in all colors and materials. Depending on the color scheme, you could use brass, aluminum, stainless steel, or even cheap-o bolts which could be painted to match or contrast with the rest of the case. The screws that come with the fan should work, too, but you might eliminate some vibration by getting bolts that go all the way through the front and back holes in the fan. If you do it this way you should put lock washers on the back (inside the case) end.
Your fan hole will be much easier if you do what you mentioned and use a hole saw. Drill out the little pilot hole in the center before you use the hole saw. This will make it less likely that the hole saw will slip, or bite at a funny angle and leave you with a jagged edge. Using a hole saw is not only quicker and neater (no "ovals" when your hand wiggles) than the jigsaw, but will save you even more time when filing the burrs and rough edges. Some cheap door trim from an auto parts store will give you a really professional look. I bought some for about $5 and was able to trim six fan holes with it.
I'm looking forward to seeing your next step!
Prof
If she dosen't want it, then I will just use it as a dedicated folding rig. All I need are computer components. 
Only problem is, is that the components cost money. 
