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Good Method for Cutting out a Window.

CyberDruid...

would you say that this method would work with a dremel routing attachment???? i have one of tho but no routing table.................
 
Woah!!! Now that's called NEATNESS!!!!1
 
Routing Aluminum of any thickness with a Dremel is problematic..they are not built for that kind of resistance and it could destroy the tool.

Yep it makes a neat and tidy opening that you can easily reproduce or use to make trim rings.
 
haha to imagine i was thinking of doing this on a steel side panel :eek:....... !!!!!

well ill have to find somebody to route this for me then thanks
 
Don't route steel you will be picking carbide out of your teeth.

Must use a jigsaw, shears, or cut off wheel for steel or have it cut with a waterjet.
 
Excelent tutorials! Hopefully I will be able to build a bigger CNC router soon and do some artwork on cases, engraving and even custom waterblocks. Made a couple on my latest GPUs but the finish is awful!
 
what type of rubber trim do you use for the rough edges?
 
Rough Edges?:slap:

Well if you do have rough edges you can use some C channel. I used to sell it by the foot but I no longer retail stuff I don't make myself.

You can probably find it at MNPCtech.com still..not sure. I buy mine in 50 foot lengths from a supplier when I do get it.
 
OK Here's my "Cut Out".

As you can see there were stencills for this case "mod"


Ahem, I might still finish it


Yes I know


Funky Spunky


Nice and Yellow


First image stencilled, not bad


It's starting to look pretty good.


It's actually quite lovely


Another pic cause it's so nice!


Instead of finishing it tho I decided to rip a BIG hole in it and paint it silver instead, Ah lovely!


Another view


Nice!


Click Link:
http://img132.imageshack.us/i/imgp1216.jpg/

Side On!


Now She breathes better
http://img35.imageshack.us/img35/236/imgp1220.jpg
 
Gosh! Wish I was as skilled as our main man CD here! Kudos to you for the nice tutorial! Might try it someday!
 
Thanks guys.
 
Here's a little update showing how to take this approach one step further to make a nice little trim ring for your routed opening. The great thing about a router template is the way it eliminates all guesswork about fitting or reproducing a certain shape. Once you have put the time into the template you can make as many holes or parts as you need.

In this series of pics I am modding the side panel a of a Silverstone Sugo for a client. I'm enlarging the opening and making a two part bezel or trim ring of aluminum and UV reactive acrylic. The Aluminum Bezel fits over the Acrylic Bezel so only the edge shows and glows and functions to hold down a piece of powdercoated hex mesh over the opening.


sugo5001.jpg

Starting off by taking a piece of 3/4" Melamine and lining up the side panel where I can mark the cutout. The Melamine will be my router template for the side panel, aluminum and acrylic bezel pieces.

sugo5002.jpg

Once I have the side panel where I want it I mark the inside of the window as well as the outside of the panel to facilitate alignment later.

sugo5003.jpg

The new opening is just taller and uses the existing sides of the opening. But it needs to be perfectly symmetrical and fall exactly on the panel.

sugo5004.jpg

Using a trisquare I find where the tablesaw blade will cut when jacked all the way up. This is prep for a drop cut to start the template.

sugo5008.jpg

Tablesaw drop cuts completed I can now finish it with the jump up and down saw.

sugo5010.jpg

Rough cut completed and now it's time to block sand it true.

sugo5011.jpg

sugo5012.jpg

sugo5013.jpg

Perpendicular and straight and flat. Ready to use as a router template.

sugo5015.jpg

sugo5016.jpg

Realigning the sidepanel to mark the waste material I will cut out with the Fein Multimaster.

sugo5018.jpg

Waste material remived. I only want to route 1/8" of waste from the panel for safety and for the best results.

sugo5021.jpg

Stuck to the template with DS tape.

sugo5022.jpg

sugo5025.jpg

Routed.

sugo5028.jpg

Pattern for routing the outside of the trim ring or bezel that secures the mesh over the opening.

sugo5030.jpg

sugo5031.jpg

sugo5032.jpg

Bezel blank routed and removed from template and now I am removing the waste material from the center using a step bit in my cordless drill and the Fein Multimaster.

sugo5034.jpg

Bezel fixed to the template ready to route.

sugo5035.jpg

Completed bezel. Ready for powdercoat just about.

sugo5036.jpg

Matches opening in side panel exactly.

sugo5037.jpg

Cut a piece of powdercoated mesh.

sugo5039.jpg

Just about a finished product.

sugo5041.jpg

Only piece left to make is the UV Reactive Blue acrylic bezel that fits under the aluminum bezel. I'd like to figure out how to hide the screws under that aluminum bezel...I think that would look really trick. The edge will flouresce naturally and any UV light source will make it really glow.
 
as usual nicely done
 
what kind of router and bit did you use to cut those holes?
 
I should be visible in the pics. Carbide Edged Two Flute Flush Trimming Bit. Thanks guys.

I've got a mass of vids uploading but my internet connection is dead slow and it will be quite a while.

If you are interested in more tips and tricks about this process check out my YouTube channel: http://www.youtube.com/user/CyberDruidtheModGod?feature=mhum
 
Remember guys the most important tool to have when doing jobs like this, Is a big mug of coffee!
 
Great work CyberDruid and i love your workshop!
 
Nitro-Max said:
Remember guys the most important tool to have when doing jobs like this, Is a big mug of coffee!
Click to expand...
And big fat seegar
Nitro-Max said:
Great work CyberDruid and i love your workshop!
Click to expand...
Me too now that the damned Stink Bugs are out of it.

I am getting ready to do some more PC modding shortly...Armorsuit in black and white.
 
This is pretty neat, keep going man keep it up and keep sharing
 
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