Since no one was interested in essentially a free A2400 Thermaltake Armor door, I decided to experiment upon it to see what went wrong. If you revisit my first post, you will read my initial discussion of my attempt to widen the holes on the door to fit the bezel of the faster 25cm fan I ordered, with the following results:
You can clearly see the crack that was created by the drill bit. Well, I tried to widen the other holes, this time drilling from the other side (plastic side), as my roommate suggested. I was able to drill the rest of the holes much easier, but none of them go through metal like the first one.
Only one of the remaining 3 holes cracked while drilling, as you can see in the upper right.
(That is my roommate playing MVP Baseball 2005 on the Game Cube, if you must know.)
And here is the door with the bezel that now fits:
As you can see, the bezel covers the new crack that was made, and much of the original crack. I think the bezel looks pretty sweet in there, and as such I am pondering buying another A2400 door and having another go at it.
For those of you who wish to do this mod yourselves, I suggest drilling from the back (plastic side) first, as it reduces the risk of cracking. I have noticed that when drilling, the plastic will rattle against the metal outside, and I believe this is what causes the cracking, so if there is a way to separate the metal casing and the acrylic, then you would be in business.
Just thought I'd share my experience so no one else makes the same mistakes!