I didn't get as much accomplished as I had planned the lady had quite the honey do list for me this weekend and she just doesn't understand the importance of modding.
Once I get started on what I am doing I become exceptionally focused and forget about the pics so they are pretty limited, I will narrate to fill in the blanks.
Had planned on doing some sleeving but thought to myself why do that it is quite work and I can do it any night after I get home without worrying about waking my fiancee.
I printed a sketch from solidworks to use as a template for drilling holes. I drilled 3/4" holes in each corner for the arbor of my 1 1/8" knockout punch kit
and used the punch to get a nice clean radius. I then removed the template and used a straight edge and exacto knife to cut the tape. I used a jig saw
to rough cut the panel to within about 1/16" of the tape and a file to where a tiny bit of black was still visible when viewed using a magnifying glass. I used
a piece of white paper behind the panel for contrast when checking how much material still needed to be removed). It isn't perfect yet but since I will be
using a piece of lexan that has a step routed in it so the front of the lexan sits flush with the outside of the panel I can't determine where the final fit should be.
I have done this before and found it was easier to fine tune the panel than it was to try and nibble at the edge of the lexan with the router/dremel.
Drilling template for fan
Drilled #25 holes and tapped the panel for 10-24 cap screws, mounted the fan, traced the inner diameter to use as a guide for the rough cut with the jig saw,
and used an exacto knife to cut along the trace.
Rough cut at this stage, need to file it down to the tape line.
You may be wondering why I placed the fan all the way at the front instead of in the center like in my original render. Well when I decided to go SLI placing
the PSU the way I had originally intended went away and it will now be at the top rear with the fan facing up/down instead of front/back. I checked it today
to make sure I have room and it is TIGHT, VERY TIGHT but it will fit.Edited by Re-Evolution - 8/5/13 at 1:31am