cutting a metal case

[Force Flow]

What kind of blade should be used on the case with a dremmel tool? What other equipment can be used to cut a case?

[David14259]

Any blade with small teeth should work...you'll also need some kind of sanding blade or sand paper to smooth it out. You can also use a small hand saw like a jig saw.

[Cricket]

For the Dremel Tool, use the reinforced cutting wheel, not the regular one.

You can also use a jigsaw (or sabresaw), a hole saw attachment for a regular drill, a sheet metal nibbler or you can take the case to a metal shop and ask them to make the hole with a metal punch...makes a really clean hole.

Cricket

[Panama Red]

There's a somewhat new tool becoming popular with hobbyists called a Rotozip. There are several manufacturers of similar products. Allows you to drill a hole and use the side of the specially designed bit to cut out any shape you want. Ajustable depths of cut and a surface contact jig, much like a router make these things real easy to use. Here's a link to Rotozip's web site. There's several other brands like this. Home Depot, Menards, Lowe's all have these, even for rent.

http://www.rotozip.com/index.phtml

[doctorgonzo]

I used the fiberglass reinforced cutting disk on my Dremel to cut a hole in my case. You will need a file or sandpaper to smooth out the hole, though. Using a cutting disk by itself doesn't lead to very round holes.

As was mentioned before, a metal nibbler can also be used. I saw some at CompUSA for pretty cheap.

Then there's a plasma cutter...

[Propain]

I just used plain ole tinbanger snips then wrapped some chrome car door trim around the cut.

[Force Flow]

Great! Thanks guys