Made a little progress today.
Here's a final shot of that stock bezel for posterity:
Disassembled what was supposed to be disassembled on the bezel, and then assembled my supplies:
No turning back now! For the record, plastic is much softer than aluminum:
Test fit. Uh oh. We have that recurrent alignment problem:
Time to take it down to the bare chassis. I snapped a pic of one of the fan assemblies, just because I thought it looked cool:
Some more rotary work on the plastic, making way for the new power switch plate... I don't know how I managed to do this on plastic:
Taped off the front of the case chassis and test fit one last time before I laid out my cuts:
I cant remember where I saw this, but I'm pretty sure it was here on Overclock.net. I used the rotary for my pilot holes before I tore in with the jigsaw:
Props to whoever showed that off. Speak up if you pass by. I owe you a rep. That worked a treat:
I ran into a lot of clearance issues for the bulgin style switches I have planned. One of those is on the way now too, so I can play around with it. Hopefully I wont have too many issues getting three of them to fit up there. If not, the dead space where the Ultra logo is now is wide open. some of them may end up down there.
After virtually no filing, (thanks to those handy rotary starters for the jigsaw), here's what I got. Remarkably, despite all the metal I have removed, its still very sturdy:
And, a parting shot with the bezel fitted again:
That's it for today. I have factory 3.5" bezels getting epoxied back into place for the night. They're going to be covered over with fiberglass eventually, but I wanted them to have a sturdy base for the sanding work and drilling that needs to follow.
I have some minor metal fabrication to do for the new fan mounts and the Sunbeam mount, but I'm waiting on my metal order to ship, so that will probably be next week. I have a plan for the Sunbeam mount that will let me play with my new bender. (I'm going to counter-sink the new knobs slightly into the curved plastic front bezel, and will need to push out the mounting plate for the controller a bit from the front of the chassis to pull this off).
'til next time folks.