Good Method for Cutting out a Window.

alphadog0309 · Feb 25, 2009

CyberDruid...

would you say that this method would work with a dremel routing attachment???? i have one of tho but no routing table.................

spearman914 · Feb 25, 2009

Woah!!! Now that's called NEATNESS!!!!1

CyberDruid · Feb 25, 2009

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.

alphadog0309 · Feb 25, 2009

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

CyberDruid · Feb 25, 2009

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.

MohawkAngel · Feb 25, 2009

I would suggest to drill a hole and put some TNT. Ok it will blow a round hole but round windows exist too

CyberDruid · Feb 25, 2009

You need to do it like this then: http://www.youtube.com/watch?v=Yjbz6XXxKTs

Keny_Robert_Keen · Aug 22, 2009

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!

Sean8 · Aug 23, 2009

what type of rubber trim do you use for the rough edges?

CyberDruid · Aug 23, 2009

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.

1933 Poker · Nov 4, 2009

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

neoreif · Dec 5, 2009

Gosh! Wish I was as skilled as our main man CD here! Kudos to you for the nice tutorial! Might try it someday!

CyberDruid · Dec 5, 2009

Thanks guys.

CyberDruid · Sep 29, 2010

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.

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.

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.

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.

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.

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

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

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

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

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

Stuck to the template with DS tape.

Routed.

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

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.

Bezel fixed to the template ready to route.

Completed bezel. Ready for powdercoat just about.

Matches opening in side panel exactly.

Cut a piece of powdercoated mesh.

Just about a finished product.

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.

MKmods · Sep 29, 2010

as usual nicely done

copenhagen69 · Sep 29, 2010

what kind of router and bit did you use to cut those holes?

CyberDruid · Sep 29, 2010

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

CyberDruid · Oct 1, 2010

Here are the vids of the process

http://www.youtube.com/watch?v=VFKdB2ke6i4
http://www.youtube.com/watch?v=XYIkRz07SJc
http://www.youtube.com/watch?v=LlScBMamcCo
http://www.youtube.com/watch?v=nEXqtuKOJiQ
http://www.youtube.com/watch?v=khcPJETGMXQ
http://www.youtube.com/watch?v=YstTPTMrmEI
http://www.youtube.com/watch?v=CrOJBtW4Mwc
http://www.youtube.com/watch?v=rlwSx95oqqc
http://www.youtube.com/watch?v=5kke0b0OZ_s

CyberDruid · Oct 1, 2010

Vid of the final result of the window/bezel operation

http://www.youtube.com/watch?v=v_Cj1lydZjA

Nitro-Max · Jan 6, 2011

Remember guys the most important tool to have when doing jobs like this, Is a big mug of coffee!

Nitro-Max · Jan 6, 2011

Great work CyberDruid and i love your workshop!

CyberDruid · Jan 6, 2011

Nitro-Max said:
Remember guys the most important tool to have when doing jobs like this, Is a big mug of coffee!

And big fat seegar

Nitro-Max said:
Great work CyberDruid and i love your workshop!

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.

user21 · Jun 13, 2011

This is pretty neat, keep going man keep it up and keep sharing

System Name	Mine \| Dad + Mom
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Benchmark Scores	Not Wasting Time!

System Name	Shop Dog
Processor	E8400
Motherboard	Asus Blitz Formula SE
Cooling	d-Tek FuZion
Memory	2 x 2GB DDR2 800 G Skill
Video Card(s)	EVGA 7900 GTX
Storage	150GB VelociRaptor
Display(s)	Acer 21.5 1080p LED Back Lit Monitor
Case	Working on it
Audio Device(s)	PCI SoundMax
Power Supply	Silverstone 750 Modular
Software	XP Pro SP2
Benchmark Scores	Super Pi 11.56s 1M at 4050mhz

System Name	Shop Dog
Processor	E8400
Motherboard	Asus Blitz Formula SE
Cooling	d-Tek FuZion
Memory	2 x 2GB DDR2 800 G Skill
Video Card(s)	EVGA 7900 GTX
Storage	150GB VelociRaptor
Display(s)	Acer 21.5 1080p LED Back Lit Monitor
Case	Working on it
Audio Device(s)	PCI SoundMax
Power Supply	Silverstone 750 Modular
Software	XP Pro SP2
Benchmark Scores	Super Pi 11.56s 1M at 4050mhz

System Name	Shop Dog
Processor	E8400
Motherboard	Asus Blitz Formula SE
Cooling	d-Tek FuZion
Memory	2 x 2GB DDR2 800 G Skill
Video Card(s)	EVGA 7900 GTX
Storage	150GB VelociRaptor
Display(s)	Acer 21.5 1080p LED Back Lit Monitor
Case	Working on it
Audio Device(s)	PCI SoundMax
Power Supply	Silverstone 750 Modular
Software	XP Pro SP2
Benchmark Scores	Super Pi 11.56s 1M at 4050mhz

System Name	KRK MTT-2
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Processor	Core2 @ 6.25Ghz
Motherboard	Gigabyte GA-X48-DS5 CrossFireX
Cooling	Zalman CNPS 9700 Blue LED / Zalman VF830 GPU
Memory	8GB Kingston HyperX DDR2 1066MHz 5-5-5~18
Video Card(s)	ATI HD4870 + Nvidia 9800GTX+ PhysX
Storage	80GB Seagate, 500GB GAMER
Display(s)	22" LG W2252TQ + 15" Viewsonic VG510S
Case	Goldfield
Audio Device(s)	HD Audio 100%
Power Supply	750Watts PC Power & Cooling Blue Quad OCZ Manu
Software	Windows 7 Ultimate Build 7100 x64
Benchmark Scores	Superclocked an E7300 on a P43 at 4.15GHz. Booted at 6.25Ghz.

System Name	SynChron
Processor	Intel Core i7 3820
Motherboard	ASROCK X79 Extreme 9
Cooling	CoolerMaster Hyper 212X with 2 Noctua NF-F12 fans in push/pull
Memory	4x2gb Corsair Vengeance LP 1600 CL9
Video Card(s)	Asus GTX 770 DCu2
Storage	Samsung 830 128gb SSD, 1TB Western Digital Velociraptor, Seagate Barracuda 320gb 7200rpm SATAIII
Display(s)	HP x2301 LED
Case	Corsair Obsidian 750d
Audio Device(s)	Asus Xonar Essence STX
Power Supply	Seasonic X - 660Watt Gold
Software	Windows 7 Home Premium 64-bit

System Name	Crossflow III
Processor	AMD 965 (4.04Ghz)
Motherboard	Asus Crosshair III
Cooling	Air
Memory	4 gigs Mushkin 7-7-7-20@1T
Video Card(s)	single 9800GT
Storage	Raptor 150's in Raid0
Display(s)	LG Flatron 24"
Case	Custom
Audio Device(s)	AuzenTech X-Raider W/OP637
Power Supply	Custom modded Corsair 750HX
Software	Win 7 64/Solaris Utility
Benchmark Scores	3DMark06--21963 so far

System Name	ASUS ROG Zephrus M15
Processor	AMD Rhyzen 7 4800HS
Memory	16GB
Video Card(s)	Geforce RTX 2060
Storage	1TB

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Display(s)	Acer Predator XB271HU
Case	Thermaltake Core X71
Power Supply	Corsair RM850 80 plus gold
Software	Windows 10

Good Method for Cutting out a Window.

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