I am planning on getting my case side panel cut with a custom design: perhaps some cool text or something abstract.
I was wondering what the best method of cutting is?
I want a real smooth edge around the cut with as little damage to the panel as possible, but it can't be ridiculously expensive.
I have heard about laser, water jet, cnc, jigsaws and dremels - but I am not sure what would be best.
Any input from people who have done mods in the past would be a great help.
Also, I will want to cover the cut with some acrylic (most likely) and wonder would it be better to mount it behind the cut or at the front? With screws or with adhesive?
Thanks a lot guys.
What tools do you have? You don't sound like the kind of guy who has access to or any experience with a CNC machine of any kind, so LASER, waterjet, CNC, etc. at all out. That leaves jig and dremel. If you have a dremel, use the router attachment with a metal cutting bit. To prevent damage to the panel, cover the whole thing in masking tape. You can draw your patter directly on the tape, too. You have to be careful though, so you don't rip up the tape as you cut. There are good ways to use a jigsaw, but the dremel is easier to do details and not wreck anything. Remember to finish up with a file.
I would suggest putting the plastic (use glass if you can! it stays clearer longer and doesn't scratch as easily) on the inside with adhesive. This way you get your cutout pattern by itself with no exterior mess to muck up the look. If you want something colored, use a theater gel.