Hacksawing A Hole Into PC Case (Not Buying A New Case)

[Roasted Bunny]

So, my new PSU has a power on/off flip switch and it’s blocking it from going into the case.

It would be ideal if I can leave the motherboard in there, but I can remove it if needed.

[Roasted Bunny]

Postat inițial de Talby:

Postat inițial de §hλŋqʂ:

The Swiss army knife of power tools... Dremel Multi-Tool. It's the go to for all serious case modders and has a ton of other uses as well. Definitely worth the investment if you consider yourself handy. Otherwise if you don't care about how it looks, use a drill with a good bit and make a mess out of it.
Always remove all components when doing something like this and clean-up carefully afterwards.

https://shop.dremeleurope.com/gb/en/products/tools?SYSTEM=multi-tool-system

+1 - Dremel for the fine / precision cuts, and a Rotozip for the big cuts. Best tools for the job.

Sure it easier to just get a new case and move parts to it, but there is a certain satisfaction to case mod to what you want to achieve in both engineering and artistic perspectives.

Yeah, and seeing a 15 year old PC in a 2018 case will be a little bit odd.

Postat inițial de Wolfie:

Postat inițial de Roasted Bunny:

I think I know someone who has one.

Do they also have a Shop Vac?

When you cut through metal, you'll inevitably create fragments and shrapnel called Swarf. Generally speaking this stuff is electrically conductive, so you don't want it anywhere near electronics. At the very least you'd have to strip the case down, including removing the Motherboard and all other internal parts. And after cutting you'd have to clean it thoroughly with a Shop Vac and ideally a large magnet as well..

It would be quicker, easier and potentially even cheaper to buy a basic case. The case would also cool much better, and wouldn't have a massive rip-saw hole in the back.

No, but I have a vacuum.

[Monk]

A dremmel is probably the best bet, and they are awesome, I wanted an excuse to get one for years and found it when I wanted to / needed to create a hole in the back of my case so I could help bleed it (i made a bad job of it lol but it works) and now I have an awesome new toy to boot :)

[Carlsberg]

If you want to do it cheaply, strip the case and mark out the rectangle for the switch. Use a small drill bit (about 1/16") and drill series of holes inside your rectangle, knock out the piece and smooth edges with small file (or emery paper wrapped around something suitable). Case metal is soft so you could use a nail to punch mark the drill spots this will stop the drill from slipping.

[Morethan2Letters]

Start a pilot hole and use tin snips. Or better yet, buy a real case.

[upcoast]

Postat inițial de Advanced3:

Start a pilot hole and use tin snips. Or better yet, buy a real case.

This is the best of the ideas ^, minimal metal bits flying around.

I've had to cut out bits of the backs in the past and manual cutting ie tin snips / all purpose cutters let you control the mess.

Ps,

Like others said a cheap $10 case or even free at a PC recycling depot might be an easier fit.

[Roasted Bunny]

Postat inițial de Senpai:

drill with a large drill bit, or the dremel metal cutter attachment

I’ve decided now to use a hacksaw.

[Talby]

Postat inițial de Roasted Bunny:

...I’ve decided now to use a hacksaw.

Another good tool for the job, what I do is use masking tape on both sides of the area to be cut and re-draw the outline on the tape. Helps keep the metal frags from spreading during the cut.

Surprised at all the new case recommendations when all is needed is a very small cut to make the new PSU fit. I do that all the time on pre-built cases when re-use is desired. Never had a problem cleaning up the metal bits left over. <shrug>

[Roasted Bunny]

Postat inițial de Talby:

Postat inițial de Roasted Bunny:

...I’ve decided now to use a hacksaw.

Another good tool for the job, what I do is use masking tape on both sides of the area to be cut and re-draw the outline on the tape. Helps keep the metal frags from spreading during the cut.

Surprised at all the new case recommendations when all is needed is a very small cut to make the new PSU fit. I do that all the time on pre-built cases when re-use is desired. Never had a problem cleaning up the metal bits left over. <shrug>

What do you do to remove the swarf? (Metal bits)

[Talby]

Once you're done with the cut I usually blast it out using a compressor (50psi+ good enough) or if you have any canned air that works too or vacuum out as best you can. Then if you have a swiffer use that all over as much as you can. Get a scrap cotton cloth washcloth, old shirt, whatever then get it wet / ring out as much as possible (just want it moist enough to pick up any crud) and swipe up all the flat areas and just be careful on the cuts can get a bit sharp so some thick working gloves may help there. Dry up the best you can (paper towels, old towel or any dry cotton cloth) then blast it with air once more (helps with drying out). Let it sit for a bit, should be good to reassemble.

[Bad 💀 Motha]

Yes I see what you mean:
http://www.3dvelocity.com/reviews/dellgx280/info/Dell%20Optiplex%20GX280%20Review1_files/image007.jpg

But yea these are ATX PSUs however.

What I would do is cut away that whole rear plate, as long as it's well within the screw mounting holes, for stability reasons. This way you can be assured that part of the case doesn't interfere with the PSU's exhaust mesh, power cable connection, or the switch. As modern PSUs tend to have a completely open back side, to exhuast the hot air; unlike how the old 20pin ones were with the 80mm exhaust fan on them.

To smooth out the sharp edges after cutting away the main area,
use a de-burring filing tool such as:
(for reference purposes)
> https://www.amazon.com/dp/B074Z7LCD2
> https://www.amazon.com/dp/B01MRND677

If you're going to be doing metal cutting on a Case, remove the Motherboard and PSU entirely from the Case first to ensure no metal shaving gets on them, as it could create a conductive "shorting" point due to being bare metal shavings and such. When all cutting and de-burring it done, use an air-blower to completely clean Case of any further dust/debris; then go and head and reinstall the parts.

[Jamebonds1]

How big hole to drill are we talk about?

[PATENT]

Woudn't it be easier to just buy new modern case like NZXT S340 for 80$ compatible with pretty much everything instead of drilling holes in old Dell case?

[Bad 💀 Motha]

Why even an $80 Case? Plenty of decent ones for old potato PC like that for under $40
But yea a new case would be easier and best. However this presents another issue. Properly connecting the New ATX Case Front I/O connectors to the Dell Motherboard; as you'd have to ID the pinout on that Dell Motherboard to properly connect things from new case, such as the Power Switch

[Talby]

Postat inițial de Deval:

Woudn't it be easier to just buy new modern case like NZXT S340 for 80$ compatible with pretty much everything instead of drilling holes in old Dell case?

Easier? Yes. Just as satisfying? Not for me, every time I use a Rotozip or Dremel I always have to brush my teeth to get all the metal bits out. Can't seem to wipe off the ear-to-ear smile I have when I use them.

[PATENT]

Postat inițial de Talby:

Postat inițial de Deval:

Woudn't it be easier to just buy new modern case like NZXT S340 for 80$ compatible with pretty much everything instead of drilling holes in old Dell case?

Easier? Yes. Just as satisfying? Not for me, every time I use a Rotozip or Dremel I always have to brush my teeth to get all the metal bits out. Can't seem to wipe off the ear-to-ear smile I have when I use them.

Is drilling a hole in pc case satisfying? :P