The modding begins.
In the next few days, I will start cutting the side panel. I am waiting for my dad to bring the jigsaw back from his workplace. As soon as I get it into my hands I will start the cutting. I am planning on documenting the whole procedure. I am going to write and article about it. I would like to submit the final draft of it to the administrators of this site, in hopes they will put it in the guides section as a how-to. Maybe, if I screw up, it could be submitted as a how-NOT-to.
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EDIT:// The case that I am modding is not the one she is currently using. It is a left over case from the an older computer. I like the design of the computer a lot. I wanted to mod it even before I found out that she was looking for one. Even if she dosen't like it, no skin off of my back. Just money out of my wallet. :banghead: 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. :banghead: Heck I was thinking of modding her current case to be used for folding.
Go to Lowes or something nearby and take a look at what they have. Maybe if you find the right person they could give out some advice.
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
I really won't a thin chrome window molding. The three colors that I want to use are chrome, black, and blue. I want to paint the frame blue as well as some of the front features. I also want the fan on the front chrome along with the molding. I am probably going to ditch the idea of having two 80mm fans on the top of the case, instead of that I will put a 120mm fan. Both the fan on the front and the fan on the top will be chrome. Hopefully my father will finance the mod. Because as of right now I only have 25 dollars american in my wallet. I have just finnished redesigningg the top of the case. It will have an inch of distance from three out of the four sides. The window will extend one inch over top of the PSU. It will just be a plain oval. I decided not to do a fancy design on the top of the case, in fear that I will botch it. After all, it will be the second most seen part of the case. It will most likely spend most of it's time in a cubby hole. I can't wait till I get that 80mm hole saw. I am going to use it on my current case as well as the one I am modding now. I want to add a blow hole for my current case, and cut out those dumb ass case grills that block 90% of the air flow. So my current case will have 4 80mm fans, and my sister's will have 2 80mm fans as well as 2 120mm fans.
I think I know the screw caps that you mean. You should be able to use a regular screw for those. Just check what size you need.
Acrylic is much better to use than plexi.
Good luck with teh modding
Kristof2
Kristof2 is right - the things you're talking about are threaded to work with standard bolts.
They are called "Acorn Nuts".
Prof
other things I can tell you that it makes for a nice neat look but
I think you'll have trouble due to the tight radius of some of your
corners. I used an 80mm fan from an old power supply for the
blowhole on the top of my case. No fancy lighting effects from it
but it moves a lot of air rather quietly. It was the single most
effective thing for bringing the case temp down.