Thx a lot for the link, that site helped a lot. I'm going to cut 3 blow holes out in a case that im modding, i bought it from scratch, $20 and now I'm painting it and putting blow holes in it.
Would you use the same stuff to cut out a design in the side panel ?
Also where can you buy the glass window to install on the side.
Depending on the strength of the tool/blade used and the thickness of the side panel, you may well be able to cut a window in the panel. My dad has mod'd his case by adding a few windows, and he used that same tool which you see in those pics.
I'm not sure where you could get fan grills from in the USA, as I'm from the UK.
Newegg, Pricewatch and Directron seem to be popular with the members here.
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If you are cutting 80mm blow holes, I recommend using a 3" hole saw, because you will get a perfect hole a lot easier than with a Dremel type tool where you have to follow a line. I used a hole saw to cut my blowholes, and they came out perfect. Just my $.02.
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I just use a jig-saw with a fine toothed metal cutting blade. I clean it out a bit with some sandpaper. It might not be perfect, but if you are any good with a jigsaw it is pretty easy and it cuts fast.
This is my most recent case mod (yup, I got to pimp it again ) and the blowhole and window was cut with a jig-saw in a few minutes:
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I tape an octagonal template I whipped up in AutoCAD and trace it out with my dremel- about half the lines get cut through, and the rest scored- when the tabs are bent back, it creates a very slick & professional looking octagonal hole that matches an 80mm or 120mm fan perfectly I don't bother with guards on my cheap-speed 80mm fans, but the fan guard works fine like this too.