Case modding tips for a complete noob

[Sauron]

Hey forum! I was considering the idea of modding my old pentium 4 rig for the fun of it and to gain some experience as in the future I might have to mod my main pc to allow more fans on the side (I will eventually go for crossfire and the gpus are too big to allow a fan in the only location available in my case's sidepanel). The problem is that I've never done anything of the sort.

 

1) I have no idea of what to use to cut pieces of the case off (screw holes are easy), and I don't know if fan holes are better left with some sort of grid on or just big holes where the air is supposed to go in (or out).

 

2) If I have the choice, are there any real counterindications to having the fans be on the outside on the case aside from space considerations? How would I go about applying fan filters? Do I really need them?

 

3) Lastly, in case I decided to go for a window (be it full sized or just partial), what material is best used for the transparent part? since it's a "for fun" mod I would like something that isn't very expensive, it doesn't have to be the prettiest thing in the world as long as you can see through it and won't break by staring at it. Can I mount any fans on the window itself?

[Oshino Shinobu]

1) 

 

2) Not really much difference. Fan filters on intakes are nice, but not necessary. 

 

3) Acrylic is the best material. You can buy sheets of it very cheap. It's also called things like Perspex, Plexiglass and a few other names, but the plastic of all of those is almost always acrylic. 

[Sauron]

-

 

Thank you for the answer and how would I go about cutting in a straight line?

[Oshino Shinobu]

Thank you for the answer and how would I go about cutting in a straight line?

For the window? 

 

Best way is to mask off the entire side panel, then mark the lines for the window. Use a dremel to make a small starter cut, then use a jigsaw to make the rest, moving slowly with a metal cutting blade. Stay well within the lines, then file and sand the edges to clean them up and make them straight. You can use some rubber U-Channel to make the edges nicer if you mess up, but it's not really needed. Just take your time and move slowly. Measure twice and cut once, as they say. 

 

For mounting the acrylic, bolts are the most secure and potentially really nice looking way, but drilling acrylic can be hard, in particular with thin sheets. Easiest way is to use something like 3M double sided tape.

[terrytek]

Thank you for the answer and how would I go about cutting in a straight line?

Bandsaw?

[Sauron]

For the window? 

 

Best way is to mask off the entire side panel, then mark the lines for the window. Use a dremel to make a small starter cut, then use a jigsaw to make the rest, moving slowly with a metal cutting blade. Stay well within the lines, then file and sand the edges to clean them up and make them straight. You can use some rubber U-Channel to make the edges nicer if you mess up, but it's not really needed. Just take your time and move slowly. Measure twice and cut once, as they say. 

 

For mounting the acrylic, bolts are the most secure and potentially really nice looking way, but drilling acrylic can be hard, in particular with thin sheets. Easiest way is to use something like 3M double sided tape.

 

Thanks a lot, might post the modding on the forum if I get around to actually doing it (it's a bit of an investment for an old pc like that, but I'll probably be able to spare the money no problem).