What are you using to cut your case?

[jmarin]

Forgive me if this is the wrong forum, and if it's been posted before as I couldn't find a thread on this. I'm curious as to what people have used to cut their cases with, specifically aluminum cases. Most of what I've seen has been with a Dremel, but no real consensus on the bit used. So what are you all using and what do you think gives you the cleanest, most precise cuts? Thanks in advance.

 

[Kmpkt]

I personally rough out with a Dremel and then hand file the details.

 

[jmarin]

I personally rough out with a Dremel and then hand file the details.

Do you use a specific disc or bit?

 

[Phuncz]

I use this: http://www.knipex.com/index.php?id=1216&L=1&page=group_detail&parentID=1369&groupID=1412

It allows to munch a little over 1mm thick panels and doesn't deform them. I like to use manual tools more than power tools. One of the precautions needed is to protect the surface for scuff marks but it allows quite some precision and lacks the tennancy to skip across the surface.

 

[jmarin]

I use this: http://www.knipex.com/index.php?id=1216&L=1&page=group_detail&parentID=1369&groupID=1412

It allows to munch a little over 1mm thick panels and doesn't deform them. I like to use manual tools more than power tools. One of the precautions needed is to protect the surface for scuff marks but it allows quite some precision and lacks the tennancy to skip across the surface.

Can you use that to cut a hole in something? (After starting it with a drilled hole) I can't tell if you can get the tool into a tight spot or not.

 

[Phuncz]

It needs about a 5mm hole if I remember correctly. It's not good for circular stuff, that's where you'd want to use a holesaw or a jigsaw for. It is however very good at straight cuts: https://smallformfactor.net/forum/threads/xigmatek-nebula-c-matx-mod.619/
I refer to it in that thread as "The Nibbler" but he also answer to Mr Nibbles and Gobble Gobble.

 

[confusis]

I use the power of well placed pokes.

In all seriousness, my go to is a jigsaw for rough work (much better with bulk cutting aluminium than any rotary tool), dremel for finer work, and then file to fit.

 

[phaelax]

For metal, you can use an angle grinder and cutting wheel if you know what you're doing and still get clean straight cuts. I did a lot of steel fabrication in the army, so I'd use a plasma cutter if I had real thick metal or intricate shapes to cut. I've used a torch too, but that usually leaves me with a lot to grind afterwards.

At home, I'd probably just use a jigsaw as well. For aluminum, some tin snips would probably work pretty easily. Just remember to wear gloves, metal splinters suck!