Hehe, thanks pjlietz and repo.
MrQ, I knew that alignment was going to be pretty key on that whole deal there. I took a lot of precautions to keep everything on bubble.
Once I got that aluminum plate notched out to accommodate the front plastic right, I cinched it down with those four thumscrews at the top. No Idea why, but the knockouts for the 5.25's on this case can be remounted with pre-tapped 6/32 screws; so I used four of those. This way, I knew that plate would be a constant variable while I plotted everthing else out.
After that, I kept constantly placing the bezel, test fitting something, filing some more, etc. etc. Once I got a dry fit to work with all the loose pieces, I taped the whole thing down and traced out the circles for the ducts. I referenced those when I made the holesaw cuts. (Incidentally, those old school wire grills work perfect for that. The eyelets for the screws are even shaped right to give you a perfect crows foot to X out your center point).
Finally, when I went to glue the tube/front plate pieces to the backer plate there, I did it with the plastic bezel in place, and weighted them down for about an hour to allow the glue to set a little. After that, I pulled the bezel off real carefully so as not to disturb them, and clamped them down solid. You can acutally see them at current in the pics below.
I could use a little feedback here. I'm about to go silly overkill on this thing I think. I haven't done anything irreversible though...
I decided that the tube I have is too much of a beast to cut to use it for an internal "tunnel ram" for air intake. I also wasn't happy with the potential it had to muss with the bottom intake, which I like. So... long story short... I have an extra fan just begging for a home.
Too much? Stupid excess? Overkill to the point of being ridiculous?
If you think so, let me know so I can go ahead with the plan.