Full side window mod for $12

UPDATE: Added a new tutorial.

How To: Full Acrylic Side Window Tutorial

Step 1: Measuring
The first thing you want to do is determine the size of the window. If you look at your case from the side you can see where the side panel fits, and thats the size of window you'll be adding. You can either measure from inside the case with the panel off, or just measure the side panel itself.

In this pic ive highlighted where my side panel fits, and thats where i'll be putting the window.


This next pic is where I measured, using the side panel and getting the length and the height, mine was 17" x 18 5/8"


Step 2: Getting the Acrylic
So now that you have your measurements, head to Lowes, somewhere usually around the paint section is where they keep the acrylic sheets and glass cutting section. Grab a piece of this Acrylic OPTIX 1'6" x 2' Clear Acrylic Sheet, it usually runs around 8.98. Now find a Lowes worker and ask them to cut the Acrylic for you and give them the measurements you took. They will cut it for free.

Step 3: Mounting the Acrylic
Now that you're home and have your window, hold it up to your case and make sure its the right size and fits good. If it does, you're ready to get on with mounting.

The first thing you want to do is choose how to mount the Acrylic. You could either bolt it on using thumbscrews or bolts, or use something less case destructive like velcro, double sided tape, or magnets.

Using Velcro or double sided tape
This should be fairly straight forward, clean the inside edges of the case with rubbing alcohol to remove any oily substances and dust. Remove the film from the acrylic, Cut off some pieces of velcro or tape, and just stick it in place. And thats it. (Be warned with double sided tape, you might have a PITA of a time getting the window back off)



Using thumbscrews or bolts
This method involves a bit more work, the first thing you want to do is choose where to attach the acrylic to the case, I choose to use 5 bolts, and marked on my case where I would put them.

In the 2 pics below I have highlighted where I choose to mount my window. (note that mine were already drilled out)



Now that you've chosen where to mount the window, there's 2 options, you can use thumbscrews and try to self tap the holes, or use bolts.


Before drilling into your case, you should remove all the components inside first, that last thing you want is to drill into a radiator/fan, or get metal shavings on everything


Using thumbscrews

Thumbscrews for PCs tend to run size 6/32, what you want to do is use a drill bit slightly smaller than the thumbscrews, then drill the holes into the case where you chose to mount the window. Now try and slowly screw in the thumbscrews, if they self tap they will be a bit hard to screw in, but as they tap the hole they will start to go in smoother. Do this on all of the mounting holes you had chosen, if the thumbscrews wont self tap, continue to the next step using bolts/tapping.

Using bolts and a hole tap
For this method you'll need to get a set of bolts. The bolts I used were size 10-24 and1/4" length. To start you'll want to get a matching tap for the bolts, again I used a 10-24 tap, and get a drill bit just slightly smaller than the tap.





Now you want to start by drilling each mounting hole using the drill bit, once you have all the holes drilled, its time to tap them. Insert the tap into a mounting hole, and while holding the tap straight, apply mild pressure and turn it clockwise like you would a screw. Keep doing this and the tap should work its way into the hole adding threads. You can usually stop when the tap is about 1/2 way in. Slowly back out the tap, and try to screw in the matching bolt, if it works, continue to do this on all the mounting holes.




Once you have the holes tapped, its time for drilling the mounting holes in the acrylic.

Drilling mounting holes in the Acrylic

So now that you have your mounting holes all ready, its time to get the window holes drilled. Position the acrylic window on the side of the case where it will be mounted, tape it in place using masking tape, or another tape that wont leave sticky residue on your case. Since the film that comes on the acrylic is partly transparent, you should be able to see the holes behind the acrylic you made, mark them with a marker.

Note: You want to use a drill bit just slightly bigger than the one you used to drill the holes in the case, it will make mounting the window much easier


Now take the acrylic back off the case and set it on something soft, I used a piece of cardboard. Drill holes in all the spots you marked, just make sure to not apply tons of pressure, and go slow. This acrylic doesnt tend to chip when drilling, but better to be safe then sorry and need a new piece of acrylic, just take your time.

After you're holes are drilled, reposition the acrylic on the side of the case and try mounting it using the bolts/thumbscrews, if it mounts ok, then youre done, you can remove the film off the acrylic and remount it.




To cover up most the original mounting holes for the stock side panel, I cleaned the edges of the case with alcohol, and went over wiht with 2 layers of electrical tape. Also if you need a tap set. I got mine from my local Harbor Freight for around $15. Tap and Die Sets at Harbor Freight Tools
Edited by Shaefurr - 9/20/12 at 11:34am

Ya I hear ya, im sure there's tons of ways to attach the panel, this was my original plan. In the end I just went with the simple nuts and bolts though since I never really open my case except for every few months to clean it.

Yeah I tried, I have a tap/die set but the edges on my case are like 1/16" thick.

Sorry should have mentioned this, I stuck the bolts inside sticking out, and held them there with some hot glue, then just stuck on the acrylic and fastened the nuts.

I was thinking of trying to use some epoxy to attach nuts on the inside, then use thumbscrews. Not sure how it would hold though.

EDIT: Guess I cant try it tonight, thought I had some JB weld laying around but can't find it ;p
Edited by Shaefurr - 9/16/12 at 6:39pm