ok, if you are going to use the dremel type rotary tool, i HIGHLY suggest that you get yourself some of the fiberglass reinforced wheels. the ones that came with my dremel are REALLY crappy, and explode under NORMAL use. NORMAL USE! the ones i am talking about are these.. <A HREF="http://www.dremel.com/productdisplay/display.asp?sku=426&color=cc0000" target="_new">http://www.dremel.com/productdisplay/display.asp?sku=426&color=cc0000</A> they are bigger, and MUCH stronger than the ones that come with the tools..although my dremel came with ONE reinforced disc, and a bunch of normal ones...
the fiberglass ones are strong enough that i made one wheel cut 1 and a half 120mm blowholes from a standard steel case. also, get yourself some safety goggles, even if you dont think you need them...because when i had that normal wheel explode, i was wearing mine, and a piece of the wheel hit the goggle, so it saved me...saved me an eye...which i cant afford to loose. you might also want some gloves...but i havent had any problems...
also, if you measure the area you are going to cut out, and put masking tape around the area that you are going to leave, put small pieces until the hole is the shape you want, so there is multiple layers, then you will not only give yourself a guide, but protect the paint. and to protect the paint eve further, i would suggest cutting from the inside of the panel. so if the tool gets away from you, it will scratch across unseen parts. when you are done cutting the hole, take one of these, <A HREF="http://www.dremel.com/productdisplay/display.asp?sku=952&color=009933" target="_new">http://www.dremel.com/productdisplay/display.asp?sku=952&color=009933</A> and use that to deburr the hole. but be careful not to take off much metal...just the burrs. and when you are done, erase any pencil marks, and then wash the panel, so that there is no metal filings, and residue from the cutoff wheel and the grinding tip.
a tip for cutting with the fiberglass wheels. take small bites...and dont press hard. let the tool do the cutting. i suggest that you go around once, lightly, to make a slight cut. then check and make sure it is round. then continue taking small bites. this should give you the best results, and save the wheel.
is your rotary tool the RTX? because i think those are even better than dremels for this work, because they dont bog down as much under load. which is good, especially for cutting metal. and if you have never used this tool to cut metal, try it out first...on something that doesnt matter, but is the same material...this will give you an idea of how it is going to handle. like a test drive.
well, i cant really think of anything else, other than the rotary tool should be able to handle all the cuts you need to make, straight or curved...even though dremels site says not to make circular cuts with their cutoff wheels...that is just so if you hurt yourself doing it, you cant sue them...but you are voiding warranties, cutting metal, spraying sparks...if you hurt yourself, it is your fault anyways...unless the dremel itself explodes...but that is highly unlikely...very highly...hehe.
but yeah, those fans you are going to get...they have some with built in blue leds, two in each fan, for the same price as the ones without them at <A HREF="http://www.openlinx.net/cgi-bin-openlinx/PerlShop.cgi?ACTION=ENTER&thispage=page16CN.htm&ORDER_ID=!ORDERID!" target="_new">this place</A>. i would get some myself...but i have no cash...so if you havent bought your fans yet...get them...unless you dont want the lights...
i hope you have fun modding your computer, and be careful, dont do anything stupid...and measure a LOT...and check and re-check your measurements, and when you do that, you should be happy with the outcome.
GOOD LUCK!
-DAvid
-Live, Learn, then build your own computer!-
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