Adding a top mounted Window and Fan Page: 1
Today I will ge going through a quick guide on how to cut and Trim a blowhole in your case.

Blowholes are not only aesthetically pleasing, but can be a great help in creating a good airflow out of your case.

Final result

This is the end result that we hope to achieve at the conclusion of this guide.


Adding a top mounted Window and Fan Page: 2
Preparation:

Note: Please remove all of the innards of your PC, including the PSU. They tend not to like metal shavings at all, don't say you weren't warned. Any subsequent damage caused to the case or hardware by the user following this guide, is entirely the responsibility of the user. OC3D Forum and staff shall be held free of any liability from the following of this guide. It is posted here merely as a reference, and any information contained within is not necessarily the expressed views/ opinions of OC3D.



Materials required

*Dremel or Jigsaw (pls use safety glasses and ear plugs);
*Drill (if you're using the jigsaw, this will make the hole to start your cutting);
*Pencil;
*Utility knife;
*Masking tape;
*Measuring tape;
*Rubber moulding with locking strip (available from any rubber products stockist);
*Perspex sheetiing (preferably 5mm or thicker, any thinner and it is prone to fracture);
*3/16" washer, and
*about an hour of your time.



Step 1

First you need to measure and mark out where you want the perspex window to go, pay careful attention to your PSU position and any optical drives that may be in the way once the case has been re-assembled. Cut out your perspex using either the dremel or jigsaw, the simpler the shape, the easier it will be to fit. I recommend the jigsaw, using the dremel on too high a speed can melt the perspex. Once you have the shape you want, place the perspex on top of the case in its correct position, and use the 3/16" washer and pencil to trace the outline of the window (this will be the line, that you cut) Use the masking tape to cover around the sides of your case completely. This will keep you from scratching the panel when you are cutting out for the window.

Masking upe

Above: Case prepared for the cutting process, note the tape to prevent scratching. You should be able to see the faint pencil line that will act as a stencil when using the dremel


Adding a top mounted Window and Fan Page: 3
Step 2

I use a dremel to do all of my case modding with. If you use a dremel I recommend you use the fiberglass reinforced cutoff wheels, as they will last much longer than the standard ones. When cutting with a dremel do NOT apply too much force as this will break your cutoff wheels.

Let the dremel do the work. If done correctly you should only have to use one maybe two cutoff wheels while doing this project. Once the hole has been cut out use the deburring tool or a file to remove the sharp edges, as these may cut into the rubber moulding.


Cutting the hole

It's a good idea at this time to remove any metal filings that have spread their way through your case. Clean thoroughly!!!


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Step 3

Now it's time for the rubber gasket installation.

Start by pushing the moulding around the the metal of your panel window, and continue working your way around the entire window until it's done. Next you can peel off the protective paper that is on your plexi glass.

It's a good idea to just peel back only 2 inches or so from the edges. This prevents the plexi glass from being scratched during the rest of the installation process. The moulding should be a little long, just trim off the extra molding with a knife until the length is just the right size.

Work your way around the hole, pushing the window into its groove. Use some masking tape to hold the gasket firmly in place to ensure a tight fit.



Fitting the rubber surround

The tighter you can get the rubber moulding back, the easier the process of installing the window will be.


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Step 4

Once your perspex has been placed inside the gasket, you need to insert the locking strip. This holds the perspex firmly in place and ensures that it won't fall out. This can be pushed in with the end of a biro, or similar blunt object. The masking tape around the outside and the paper covering the perspex can now be removed.

The next item on the agenda is to mark out the holes for the 120mm fan, you should be able to make a template for the hole from thick card.

Mark out the hole with a non permanent marker including the screw holes. Cut out the hole by drilling right around it with a drill, and push the centre piece out (be sure to smooth the edges with the dremel).

Install the fan with rubber grommits to reduce possible vibration, and a fan filter (UV recommended).....VOILA.


Final picture

Well I hope that this brief guide will assist you in not only making your case just that little bit more personalised, but allowing it to perform a little bit cooler too.

OC3D Modified

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