Tools required to mod cases

[Rondog]

Im new to modding and ive got a clear acrylic cases and i want to mount a 120mm roof exhaust fan. What tools would you recommend I use, so I dont crack the plastic?

Also, what tools would I use to cut through a metal case?

[danrok]

Cutting plastics requires a negative rake angle on the teeth of the blade, otherwise it will split and chip.

There are workarounds, e.g. if using a hole saw for wood you can try using it with the drill in reverse to give a negative rake.

You can also modify steel bits with a file to make them suitable for plastic. Just file the sharp edges of the tip verticaly, so that the edge becomes flat.

Cut slowly and stop often so that the plastic doesn't heat up and melt.

You'll need to practice on some scrap plastics.

[somebodytoldme7]

you can put masking tape over whatever you want to cut and it should prevent splitting. good luck on the mod.

[danrok]

http://www.sdplastics.com/acrylic.html
http://www.bertram31.com/proj/tips/drill_acrylic.htm

[danrok]

Originally Posted by somebodytoldme7

you can put masking tape over whatever you want to cut and it should prevent splitting. good luck on the mod.

Putting tape on won't stop splitting.

[Gizmo]

Originally Posted by danrok

Putting tape on won't stop splitting.

Nope, but it can help stop the scratching that occurs as pieces of cut plastic get spun around the bit.

Also, I have quite successfully used regular saw blades and hole saws in the past while cutting plastic (plexiglass and lexan). The key is to go S-L-O-W.

Did I mention that you need to go S-L-O-W?

Oh ya, and you really, REALLY need to go S-L-O-W.

[Rondog]

Cool, Thanks for that guys. I will give it a try. WOuld a hack saw blade work?

[danrok]

Originally Posted by Rondog

Cool, Thanks for that guys. I will give it a try. WOuld a hack saw blade work?

You can get blades for cutting plastic, but they can be hard to get hold of.

A hack saw with fine teeth will probably be ok. The thing to do is to test it before butchering your nice case!

[Rondog]

I will, im not gonna jump in with a hack saw attempting to cut a 120mm hole.

[danrok]

Originally Posted by Rondog

I will, im not gonna jump in with a hack saw attempting to cut a 120mm hole.

For a 120mm fan you'll need a 115mm hole and don't forget about four small holes for the mounting screws.

[Rondog]

115mm? Hmm, fair enough, thanks for that, yeah I know about the holes to mount it.

[ntweak]

I use a rotary tool to cut all my metal and plastic. Bits are real important.
you can also adjust the speed of the tool for different materials.

I use the tape on the acrylic and lexan to have fine definate lines.

you will still have to use small files or fine sandpaper to clean the edges to makke it look clean and professional. Fan cuts are not as tedius or important as desighns.

good Luck on the future moding!!!!!!!!