Modders Toolkit: Everything You Need to Make Kick-Ass Custom Case Mods

Posted 06/27/2012 at 2:13pm | by Brad Chacos

23

Comments

Print

Banging out holes

Whether you're making a new exhaust fan or the open mouth of a fiery demon, poking a hole through a case is almost inevitable during case modding. There are several options available for making said holes, however, starting with a bi-metal hole saw set.

Bi-metal hole saw sets are specialized attachments that turn everyday power drills into badass machines capable of cutting holes of various sizes, though you'll need an arbor that fits your drill in order to use them. Most can also be used for cutting wood or plastic. "I use these to cut out fan holes and scratch-build pieces like the arc-reactor on the Iron Man build," Ron says.

That's right -- that badass Arc Reactor above was built using a simple hole saw set. (And some additional techniques, of course.) Bill Owen's actually made a video guide to using hole saw sets for case modding. He also supplied us with this handy-dandy list of conversions:

• 80mm = 3-inch hole saw
• 92mm = 3.5-inch hole saw
• 120mm = 4.5-inch hole saw
• 140mm = 5.5-inch hole saw

For fan screw holes, Bill suggests using a Roper Whitney No. 5 Jr. Hand Punch. It works fast and comes out clean.

If you're super-serious about making clean holes and have a lot of money to throw at modding, Bill recommends investing in knockout punches, specifically knockout punches made by Greenlee. "No need to deburr the edges of a hole saw or jigsaw cut anymore!" he says.

Knockout punches use elbow grease and the slow, steady pressure of tightening the punch using a screw to knock holes through metal. Various-sized sets and stand-alone punches can be found online, but be warned: they often cost several hundred dollars. You'll also need a socket wrench to use a knockout punch, and Bill recommends a wrench at least 19 inches long. (It takes a lot of oomph to punch through metal!) He's also made a video guide for using knockout punches.

Ultra-precise holes need a drill press. Drill presses remove any chance of either the drill or the material shifting, and they also work with the same accessories as a standard drill, including hole saw sets. Small, basic models can be found  for less than $100 online.

"To make sure the holes are perfectly perpendicular to the material I use a drill press," Sander says. "Not a professional one, but a low end one, which is more than enough for this kind of work. Also, drilling a fan hole into a piece of Plexi is so much easier when you use a drill press as it stabilizes the drill, which stops the blade from biting into the Plexi and causing it to crack."

Cutting Things

Rotary tools are nice, but sometimes their cutting attachments just won't do the trick. When you've got a big, long cut lined up, saws are the best way to go. Modders tend to use band saws and jigsaws. Note that different materials require different cutting speeds and saw tooth density; Plexi requires a slower, finer cut than metals, for example.

Bandsaw - "I find myself using the band saw for long straight cuts into various materials, and use a 14tpi (teeth per inch) blade for most my work," Ron says. He, like most modders, considers the tool a must-have.

Jigsaw - Jigsaws use thin, fast moving stroke-action blades. A jigsaw can cut straight, sure, but its real advantage lies in its ability to handle curved lines and scrolls as well as its overall versatility; jigsaws work well on almost any case as well as Plexi. They're also much more portable than bandsaws.

Proxxon DSH Electrical Fret Saw - Scratch modders take note: "This thing is its weight worth in GOLD!" Sander says. "It's my most used and versatile tool. I use it to cut MDF up to 20mm, Plexi up to 12mm and aluminum up to 10mm.

"The blades are detachable so you can drill a hole in a piece of material and saw from the inside. Brilliant for making fan holes, windows, ventilation slots, drive cages and what not. Also, the cuts are straight and clean and I can set two speeds, slow for Plexi and fast for aluminum."

We're almost there! The next page has even more advanced tools, links to modding-friendly service providers and some parting words by a couple of our Modderati experts.