Cutting case metal

[jay_l_a]

Hey,
Anyone know a good way to cut out a piece of metal at the back of an old PC case?
I was going to use a mini hack-saw, but I'm worried about metal shards (read: I'm lazy, the pc in question is junk, and I can't be bothered removing the components first).
Any ideas?
Thanks,
J

 

[yathink13]

I use a dremel to do all my case mods. You are going to end up with some dust/shaving no matter how you do it. Best way I can think to maybe keep the particles out of the box is put a fan inside the case blowing out and tip the case so that gravity pulls the particulate matter away from the site.

 

[orangegator]

Use a dremel tool or other rotary cutter. Cover the motherboard and components with a towel to keep out the dust and sparks created. I've done it and it's worked fine.

 

[JohnnyLucky]

I agree with yathink13 - the dust and shavings will wind up everywhere. Any chance you are going to cut a hole for a fan? I use a hole saw attached to a drill to make the holes.

 

[dobby]

yup a dremel is the way to go, get a dremel brand dremel, not a generic rotary cutting tool.

 

[huron]

I've used a drill and a hole saw for bigger holes. Other than that, I would use a dremel tool as suggested.

 

[IH8U]

Dremel, Jig Saw w/ metal blade (will need a drill for this approach), or Tin Snips (Same as before, use a drill first).

I'd go for the Dremel, less hassle, but more mess (WEAR GOGGLES) the cutoff wheels can shatter and go everywhere.

 

[yathink13]

There is actually a metal cutting attachment for the dremel that looks kind of like a drill bit. I like it alot more than the cutting discs for detail work. Just trace a template onto the metal and then i use the etching attachment to get a shallow line, then the heftier cutter to follow the line.

 

[ZOldDude]

What exactly are you trying to do?

When I build a new system I always take the new case and -remove- the exit fan cover(s) to get that extra 80% air flow (no matter how large the holes you have the "air dam effect").
I first drill out a hole large enough to insert a tool called a nibler and cut away.

 

[grieve]

Depending on the size of the hole a drill can be perfect, even better then a dremel... for say 1 inch holes..

If you need a big area like a fan opening then for sure a dremel or a router is needed... Dremel ftw. Do not try a hack saw, itll make a nasty mess of the metal, ripping it and what not.

 

[piratepast40]

If I read right, you're worried about metal "shards". Wear gloves and file down the sharp edges when you're through. Let's face it, if it's old and you really don't care about the components inside, try a 30.30 or a 38 magnum hollow point and file down those edges 🙂.

 

[roadrunner197069]

Oxygen Aceteline blow torch, or plasma cutter. LOL!

 

[jay_l_a]

Thanks for all the replies.

I'm building up an old junker from parts laying around. I'm having to change out power supplies. The case is an old Dell case, and the old power supply has no ON/OFF rocker switch.
The case only has a small hole for the power cable to attach, but the new power supply has rocker switch. Hence I need to make the hole bigger..

I'm thinking I'll go with the dremel attachment.

 

[stoner133]

Shaped charge or thermite charge

 

[Guest]

I like a tank shot =D

might be a BIT TOO BIG

but it will provide great airflow

 

[bobbknight]

Sheet metal nibbler will work, but it leaves jagged edges.

 

[grieve]

$50 bucks will get you a cheap case... same price as the Dremel

 

[4Ryan6]

Hey,
Anyone know a good way to cut out a piece of metal at the back of an old PC case?
I was going to use a mini hack-saw, but I'm worried about metal shards (read: I'm lazy, the pc in question is junk, and I can't be bothered removing the components first).
Any ideas?
Thanks,
J

Aviation Sheers work great, if you don't want to remove the internal components, start with a smaller hole in center and spiral out to your cut line removing interior cuttings as you go, this method will give a cleaner finish cut!

If you try to go straight to the finish cut line you'll get jagged results with sheers, so work out to the finish cut line, the least amount of waste metal you end up cutting the, cleaner the finished edge.