Hatch

[BobRoss]

Ok, here is my situation. I frequently need to get into my case so I can clone my system from the fresh copy I have on a separate HD I have inside my case. I keep it isolated (unplugged) so that there is no chance of corruption from any data source. I do not however have a case where the side is removable. I ended up just leaving the case open because it was a pain in the butt to take the cover off all the time and then put it back on. For reference I do this clone about once or twice a week. So I decided to cut a hole in the side and make a hatch that I could take off easily. While I was at it I decided to go ahead and do some work on the cooling system. Here is what I did:


This is what the case looked like before any work. It is an old case, almost eight years I think.



An inside shot.



I found my hatch and traced an outline of it onto the side of the case. Then I drew another line ¾” inside the outline. This will be my cut line.



I also drilled a hole in each corner so that I would not over shoot my cuts.



This is the saw that did the cutting. It was pretty quick, just make sure you have a big air tank cause it really goes through a lot of air.



Once the main hole was cut I put the hatch in place and marked the spots for my mounting holes.



I put an extra bit of metal down with the MIG welder to better hold the threads I would cut.



I used this punch to put a little dimple in the metal before I drilled my mounting holes. Actually I did that before I drilled all of my holes. It really does a great job of keeping the drill from skating all over the metal.



Once my holes were drilled I tapped threads in them with this tap.



I put down some foam tape for insulation.



Here is the hatch installed. I used thumb screws to hold it on.



Next I cut out a hole in the top for a 120 blowhole.



I had to repeat the hole on the case lid, so I made that hole bigger



I used a drum grinder to smooth them both.



This is the case as it sits now.

[GrahamGarside]

the images don't work, I don't think the forums accept html tags you need to use the [img][/img] tags

[BobRoss]

Ok that did it. Thanks!

[cloasters]

Welcome to AOA's Forums, BobRoss!

Ahh, U-Shaped case covers, I miss them so. Not, they were APITA. Very impressive mods, the new hatch looks great! I decided to go with a 92mm fan on top, there seemed to be not enough space for a 120mm.

I'm surprised that you didn't select a Nibbler for the cut-outs. Much more fun than using an old fashioned Dremel!

[Daniel ~]

Very nice job Bob! Front page stuff!

http://www.aoaforums.com/frontpage/index.php

[BobRoss]

Wow thanks Daniel. I am Honored.

Cloasters- Thanks for the welcome I really have seen some great info on this forum.
I had plenty of room for the 120. I was thinking it would look cool to have a whole row of them on top like a train has. I saw some fans with a pointy cone that would be perfect for it. But that will have to wait for "next time". In the mean time I am planning the next phase of the mods for this case.

[Daniel ~]

Entirely our pleasure! ":O}

[robbie]

Excellent work!! and welcome aboard.

[bradmax57]

Very good work