Case Modding Tutorial
Ton Khowdee, a member of CLUB SLI, has made quite a reputation as both an overclocked and a case modder, garnering "Rig of the Month" status both here at SLIZONE, as well as in the popular DIY magazine, Maximum PC. Ton takes us through the step-by-step process of modding a PC, in this 4-part series.
We now turn the reins over to Ton...
See the time-lapse videos of this project by clicking on the links below:
"EVGA Logo Creation" (9.5MB WMV)
"NVIDIA 'eye' Logo Creation" (16.2MB WMV)
"Side Panel Creation" (9.5MB WMV)
American Chopper & Pimp My Ride are just example of how enthusiasts go out of their way to take sometime they enjoy and love to the next level. Case Modding is just another example of enthusiasts giving their PC's a unique identity that is a reflection of the owner. This is a part 1 of a 4 part case modding tutorial series that will help you turn a plain case into sometime that is reflective of your personality
This modding tutorial series is designed with the average computer enthusiasts that are interested in enhancing the appearance of their computer. The tutorial will use tools and equipment that may already be in your toolbox.
Preparation:
Safety and precaution:
When working with machinery and power tools, please be sure to wear the appropriate safety gear. For this case cutting, I recommend using the following:
- Safety Glasses
- Work Gloves
- Face Mask
)
)
Part 1: Case Selection and Preparation:
The great part about case modding is that any case can be modified. The selection of a proper case will allow greater modding possibilities. Here are some items that should be considered when choosing a case:
Material:
Current case material can range from plastic and acrylic to steel. Each case material has their own strengths and weaknesses. If you plan to do a lot of cutting, aluminum side panels would be the ideal choice. Aluminum side panes are typically lighter and easier to cut.
Case Size and Design:
The physical size and factory design of the case will determine how much can be done to the case. For example, if you are planning to do intricate designs on the side panels, factory blowholes and exhaust ports may come in the way. In this situation, a case with smooth aluminum panels would be ideal. On the other hand, if you are planning on going into water-cooling, factory cut 120mm Fan holes may be ideal spots to mount the radiator.
Project Case Selection:
For this project we plan to cut designs on both side panels, as well as the top panel. We wanted a case that had large and smooth aluminum side panels for cutting. For this project we choose to use Lian Li PC-60B Mid Tower Case. As you can see, the side panels have no factory cut fan mounts. The side panels are a smooth open canvas for cutting.
)
)
Panel Removal:
Before we can transfer designs to the side panels, it has to be removed from the case. Most panels are typically secured by case or thumb screws. On some cases, the panels are held together by rivets.
)
A great way of rivet is to think of them as semi-permanent screws. Rivets can be easily removed by usining a 1/8" Drill Bit. To remove the rivet, just put center the bit in the rivet and drill:
)
The rivet will break apart once you drill into it. Once the rivet breaks apart, slowly remove the drill from the case. You will see the rivet on the tip of your bit, and will have a nice clean hole:
)
)
When you are done w/ the case mod, you can re-secure the top panel using a pop-rivet gun (approx $10), or you can just use a screw.
Panel Preparation:
Once the panels are removed, they should be prepared for design transfer and cutting. For this task we use a wide basic masking tape.
)
** If you plan to leave the tape on for a few days, you may want to consider using premium tape. **
Covering the side panel with tape will also help prevent them from getting scratched during the modding process. Once the panels have been covered, make sure to clearly label which side panel it is, along with the orientation. This step will help prevent accidentally cutting the designs on the wrong panel or upside down.
)
Basic Window Cutting:
Cutting a side panel window is one of the most common case modding tasks. The task is relatively easy, and you get a great impact by showcasing all your internal hardware. The only tool you need is a drill to make a starting point, and either a powered or hand jig saw to cut the window.
** Cut on the back side of the panel to hide any scratches **
When designing your side panel window, make sure to consider the location of the internal hardware and where the acrylic will mount to the side panel. If the window is cut too close to the edge, there will be no room to adhere the acrylic to the panel. By not cutting the window too large, there will be room to hide CCFL Tubes as well as wires.
First we do is flip the side panel over and cover the back side with masking tape and transfer a simple window design:
)
)
A great trick is to put a coin at the where the edge meets to give rounded corners.
-
)
Once your design is done, use a hammer and nail, or small impact tool to make an indentation in the side panel for the drill. Making a small pilot hole first will allow the drill to make a straight hole, and prevent the drill from walking.
)
Once the pilot holes / indentation are made, clamp the panel to a piece of wood before your drill. This will prevent the side panel from being warped or dented.
)
For the pilot holes, I used a 3/8" Drill bit. This gives me enough clearance to fit the blade from the orbital jigsaw:
)
** To make cutting easier drill enough pilot hole so you only have to focus on cutting straight lines **
After the pilot hole is drilled, it is time to start cutting the panel. Make sure to use the appropriate blade for the material you are cutting. For this part, I use an orbital jigsaw with fine tooth blade designed for cutting metal. Just as we secured the panel before drilling, we do the same when cutting. The panel was positioned slightly off the cutting board. This allows for the side panel to be supported during the cutting process:
)
When cutting, the key is to make sure not to cut outside your design. As you can see, the cuts are not perfect, but they are inside my design.
)
Once you have cut the main portion of the panel, there will be rough edges that will have to be cleaned:
)
Since the panels are made from aluminum, the edges can be easily cleaned up with a large hand file. If you have access to a rotary tool, you can use sanding drums instead.
)
After all the edges have been cleaned, remove the tape to reveal your new side panel window.
)
Text Window Cutting:
If you are comfortable with cutting side panel windows, a great next step is to cut out text.
When designing the text you will be cutting, make sure to select fonts or letters that lend it self to being cut. For example, if you were to cut the letter O or D, you mean just end up with a big hole.
For this project, we wanted to cut the EVGA logo. EVGA is a great company that has always produced top notched NVIDIA products. Great news is that the logo is an ideal candidate for cutting.
After measuring the top panel, the logo or text should be resized on your PC to maximize the size. A larger image is typically easier to cut. Once you have the design at the right size, print out a hard copy and tape it to the panel.
)
Some people may try to cut the design with the designed taped. From personal experience, I find this very difficult to accomplish. The design tends to shift occasionally when cutting, or the design separates from the top panel. The easiest way to cut the design is when it is drawn on the masking tape. To accomplish this task, I go over the outline with a ballpoint pen, while applying medium pressure.
)
When you are done outlining the design, remove the paper from the panel. You will see that there is an indentation / groove left behind from the pen. Now trace the indentation with a pen or fine tip marker. Once you are done, you have now successfully transferred the design to the side panel
)
Now the design is ready to be cut, be sure to put on the appropriate safety gear.
)
Just as we did with the side panel window, we are going to make small indentation and then drill pilot holes with our 3/8" Drill.
)
)
With an intricate design, a pilot hole makes it easier to cut the design. Here is a progress show of cutting from one pilot hole to the next.
)
Here is the rough cut made with the orbital jigsaw
)
To clean up the letters, we used 3 primary bits for our rotary tool: - Reinforced Cut Off Disk - This is used to cut off excess material missed by the jig saw - Sanding Drum - This is used to help round the curves, and clean the cut edges - Carbide Cutter - This is a great bit to make cuts in those very tight areas.
)
Here is a picture of the letter "A" after the jig saw, and then after the cut off disk was used to clean it:
)
)
The carbide cutter was used to expand the circle in the letter "A". Here is the before an after shot:
)
)
The last step is to use the sanding drum to clean up all the edges and remove the masking tape. Here is the completed top EVGA Panel
)
Design Side Panel Cutting:
Cutting intricate patterns uses the same principals as the last two methods. Here is how we apply it.
Prepare the backside of the panel by covering it with masking tape and marking the orientation.
)
Make sure to print the design you are planning to cut as mirrored and 1:1 Ratio. Since we are cutting the image form the backside of the panel, the image needs to be mirrored so it appears properly on the front side of the panel. In order to get a 1:1 ratio for the pattern, it was printed onto 4 sheets of paper. The sheets of paper were then trimmed and taped together to make on large single design image.
)
Tape design to the side panel and transfer the design. Once the design is transferred, trace the indentation, and clearly marked what area is to be cut.
)
Drill 3/8" Pilot holes for the jig saw.
)
Make initial cuts with jigsaw, leaving any difficult areas to be cut later with a rotary tool.
)
For cutting the remainder of the side panel, use a rotary tool with the reinforced cut off disc.
)
When cutting with a rotary tool, do not try to cut the material completely through like a jigsaw. The rotary tool spins very fast, and it can easily cut astray. A good way to use a rotary tool is to start it at a medium speed and score the side panel. This will create a small groove:
)
Once the groove is done, turn the speed of the rotary tool up to about 3/4. Now follow the groove that was scored. The groove will keep the cut off disk from going astray. The disk should not go completely through the side panel, but more material will be removed. Repeat the process 2 -3 more times till you completely cut through the side panel
)
Use a hand file or sanding drum to clean up all the edges, and remove the masking tape. Here is a picture of the finished
)
Finishing Up:
Case Modding is a great way to make your computer unique and stand out. Cutting your case is just one way to modify your case. As you can see, modding a case can be as simple as cutting a large side panel window, or as intricate as cutting an image.
Next month tutorial will cover how to give your panels a new color!!!
This do-it-yourself tutorial was submitted by a fellow NVIDIA fan. NVIDIA is making this tutorial available "AS IS" and makes no representations or warranties of any kind whatsoever regarding the advice given in the tutorial, demonstrations shown by the tutorial or any other content therein. This tutorial does not reflect the opinion of NVIDIA and NVIDIA hereby disclaims any liability of any nature related to the tutorial to the fullest extent allowed by law. from : http://www.slizone.com/object/slizone_cmg_part1.html
Posted in: Case Modd
