Best tool for cutting a steel case?

[Whiternoise]

Hey,

I'm starting my first window mod at the moment and i've got case, window and edgeing (thanks Kustompcs) but no implement for cutting as of yet.

I was thinking to go for the old favourite, the dremel because it's about time i got one And i don't really want to shell out money on a jigsaw that i wont use for anything else (dremel = multifunction).

If i did go with the dremel, how many cutting discs do you think i should expect to use? (one 350x350mm hole, and two 100x150mm holes - top and side)

Thanks - i'll probably start a worklog to let you guys know how it's coming along

[kopite]

I went through a pile of the cutting discs when i was cutting my Lian li aluminium case.

You can get a jogsaw from Homebase atm for a bout a fiver and IMO thats the best way to cut a hole in a case.

Just make sure you put masking tape over the aread.

[Whiternoise]

Ok i had a look on screwfix direct (i'm a bit lazy y'see)

Here's one i found that was in my price range, imo, a fiver isn't much of a guarantee that it'll hold out - and this one has a 10mm cutting threshold through steel..any thoughts? http://www.screwfix.com/app/sfd/cat/...6425&id=69240#

EDIT - oh, does steel count as a non-ferrous metal? i don't think it does (ferrite, iron for example) but just checking

[Funkstar]

How about adding this item?
http://www.screwfix.com/app/sfd/cat/...50043&id=18660
"T118A: Cuts thin sheet metal 1-3mm." says nothing about the type of metal. You should be fine with it. Might bet better to get a couple though, you don't want to break it when you are just about to finish. Yes you can break these things quite easily.

[kopite]

That looks pretty good.

ITs a lot easier to cut holes with the jigsaw than a dremel. Especially big holes.

[Butcher]

EDIT - oh, does steel count as a non-ferrous metal? i don't think it does (ferrite, iron for example) but just checking

Steel is ferrous; ferrous being derived from iron, which steel most certainly is. Non-ferrous typically means things like aluminium or brass (or well anything but iron and steel really!)

I'd agree with a jigsaw being a lot easier than a dremel - dremels are horrible for anything but small jobs and you'll spend over the odds on cutting discs anyways.

One nice tool I've used for cutting sheet metal is a pair of tin snips (also called aviation snips sometimes). You can get a cheap pair for a couple of quid that'll do for a one off job, or a decent pair for a bit more that will last. They're easy to use (just cut like a pair of scissors basically) and produce nice smooth cuts. One thing to note is they come in different colours for different cut directions, red for left and green for right. Either of them will cut a straight line or a hole, but red are probably easiest to use if you're right handed.

[RS2000]

A NIBBLER makes easy work of cuttig metal as well, i would think u'd get a lot better finish than a jigsaw.

[kopite]

Snips can give a bit of a pinched edge though if your not careful Also if your cutting a hole in the middle of something then you`ll need to cut out part of the hole first with something else to get the snips enough room to start

Jigsaws are really quick to cut holes. Plus you can cut some funky holes instead of the normal square shapes

[Funkstar]

For tin snips (or Aviation Snips) you would probably want the yellow handles straight cut ones (http://www.screwfix.com/app/sfd/cat/...89238&id=54837) The left and right handed ones do tend to want to cut a curve in that direction too.

Screwfix don't seem to have Nibblers, but i've seen them before, they should work well too, might even be easier to use than the snips

[Butcher]

Nibbler will give a rougher edge than snips (or a jigsaw for that matter), but you can get really tight corners and funky cuts with them.

If you're cutting with snips (or with anything really), you'll be wanting to mark out the cuts with a scriber first - it gives a slight groove in the metal which will guide the blade of the snips and helps prevent you veering off all over the place. I've done a ruler straight cut with green snips using a scribed line so it can't be that hard. Also if the snips are sharp you shouldn't get much in the way of pinched edges.

I'f you're cutting into the middle of something you're going to have to drill a hole regardless of tool, so that's not that big of a deal I'd say.

[Whiternoise]

Ok thanks people, i shelled out 34.99 on a Bosch Jigsaw from Focus (25% off, not bad i thought).

I'll post a piccie Needs a go with a metal file but i think it's not too bad for a first job.

Also, i've got some C-edging from KustomPcs at the moment, but i rather foolishly ahem.. made the window a bit too big ie. on the left hand side (the back) the edge is flush with the side of the case, so there isn't any room to stick my acrylic. So... do you know where i could find some edging that has two channels opposite each other? So i can fit the window in if not, then i'll work something out, but for now it would be a lot of help :O one option i thought would be quite fun would be to get some fibreglass putty, put the window on top of the panel and use putty to stick it down in relief..?

[Funkstar]

that would be epoxy putty as opposed to fibreglass putty (i use these things for work).

This stuff should stick to perspex, definitely will to steel
http://www.maplin.co.uk/Search.aspx?...54BZ&DOY=16m10

But something like their 1 or 5 minute epoxt might be better for actually sticking the window in.
http://www.maplin.co.uk/Search.aspx?...6m10&source=15

[Whiternoise]

Ah ok, the stuff i was thinking of was:

http://marinestore.co.uk/page/mrst/P...-epoxy/HA1698/

still epoxy though

[cjs150]

There is a problem with using a jigsaw - unless you back the metal firmly against somewaste wood the kigsaw can jump and buckle the metal. Dremel standard cut-off discs are a waste of time on steel cases (I know I have just blown through a pack), but the reinforced ones should work. If you have long straight cuts just use a 4.5" angle grinder to cut close to line then a metal file to get it precisely to measurements

[blknoel]

Reinforced dremel discs work too, bit time consuming though, I've tried it.

[Whiternoise]

I've been using the reinforced ones to cut the blowhole, worked a treat

I know what you mean about the jigsaw, jumps like crazy without some kind of support - also depends how fast you cut, it only jumps badly at low speed.