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Window mod questions - clean finish when cutting with dremel?

post #1 of 3
Thread Starter 
Hey Guys,

I'm planing a window mod on a black panel soon and wondering how do people get such a clean finish to a cut made with a dremel or jigsaw? Do you simply do the best cut possible and then file it down the rest of the way? Do you use some sort of stop whilst filing to get a perfect straight edge?

The panel is black, all this filing and cutting will certainly leave exposed metal, do you repaint with a little of tin of model paint or something? How do you apply it, just with a brush? How do you match the finish?!

I don't want to use U-channel.

Thanks in advance!

Brian.
post #2 of 3
It all depends how much time you put into it, if you spend a lot of time filing and sanding with emery cloth you are going to get a very nice edge, but if you rush it your going to have a nasty jagged cut. It depends on your window shape and size, but the best advice would be to use a quality tool and cutting wheel along with a steady hand. The closer you get your cut the less time you will have to spend finishing it.

Depending on your setup you may be able to use a jig to hold your tool and slides along your line, then you wouldn't need to worry about holding it. That would probably give you the best first cut if you take your time.

Here's some pretty good tutorials that actually show cutting into the case.

http://www.youtube.com/watch?v=gTDpxmGEC58

http://www.youtube.com/watch?v=9iMiH8wYTDY

The goal is to not have to repaint or touch up your case at all so you have to be careful. The taping that he shows in the video works pretty well. When you are filing/sanding remember to keep your file at a vertical or slightly acute angle so you won't damage the paint on the outside of your case.
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Mini Monster
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HyperX Savage 2.5" 240GB SSD PNY 2.5" 480GB SSD Corsair H75 AIO Cooler Windows 10 Home 
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post #3 of 3
Thread Starter 
Thanks for the info man, much obliged!

I'll be modifying the existing window in an NZXT Phantom 410 to a square about 350mm by 350mm.

I have no problem spending hours, or days if necessary, at it to get the best result I can. My main concern is getting the long straight sections very straight! Filing it down, I can foresee minute undulations along the line without using some sort of straight edge stop. Is it possible free hand?

The second thing is I've been looking at a few videos and the two you posted, the edge of the panel is in bits after its cut. So the idea is to take time getting the best possible cut but leave maybe a millimetre to file back and use the file perpendicularly or even ever so slightly angled in the way?
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