Water Jet Cutting a Case Window

B[x] · 06-28-2006, 04:42 PM

For my next build I want to take a standard case (something along the lines of the Lian Li PC-61) and cut my own window. I like the aforementioned case mainly because the side panels don't have any grills, fans, or other holes/ridges that would get in the way of a window. Also the inside of the case seems pretty open, thus allowing for a bigger window.

The window I plan to make will be a custom design incorporating the letter S (my last name's first letter) in some way, shape, or form. My initial designs were relatively simply to allow for an easier time cutting. However, I then remembered that my school has a water jet cutter that I can more than likely use for this project. At this point the whole idea of keeping it simple went out the window (no pun intended) since water jet cutters can be extremely detailed - see here for some examples. I more than likely won't be using any window molding since some of the holes will more than likely be too small for it.

For those of you that don't feel like reading up on it, these machines use a very fine stream of water (about 0.01" diameter) at absurdly high pressure (ranging from 20 to 60 ksi) to cut whatever material you need cut. They were originally designed to cut lumber but can now cut through anything ranging from fiberglass insulation to metal to food to concrete.

Now, I've never used a water jet cutter before nor do I know the specs of mine such as whether it's pure water or abrasive. However, I don't think the specs would really matter seeing as how the material I will be cutting through won't be more than 1.0 mm thick. I'm wondering if anyone here has had experience with a water jet cutter whether it was used in modding a computer or not. I did a Search on these boards looking for people that made their own windows and I only came across one mention of using a water cutter but that's all it was, a mention. From what I understand you have to import a CAD file into the machine and then do some tweaks to line it up properly as well as show it which path you want it to cut. I am well versed with AutoCAD 2006 so desiging it isn't a problem, it's getting it from AutoCAD to the panel that I'm not sure of.

I can easily obtain instruction once I get back to school but I'm really excited about the idea of using this process and wanted some input on it.

Oh, on a little side note, the computer I'm running now isn't that old so I don't plan on actually doing this build for another year or so. Right now I'm just trying to figure out if this idea will work so that I can get serious about designing the window. I'll upload some pictures of some layouts I threw together when I get home from work.

ChrisDVD · 06-28-2006, 05:16 PM

this sounds quite interessting. I was also thinking of cutting a window in my panel....but i never used a water jet cutter. It for sure would be better then using cutters

Here is a suggestions.....cut from the inside....somehow i would be scare to damamge the paint on the outside of the panel...

P11 · 06-28-2006, 05:36 PM

That sounds like a good idea...however, you have to take into consideration that the case is made out of very thin aluminum. I'm not too experienced with water jets but I could see a problem cutting the aluminum with high pressure water. There must be some type of adjustment to reduce water pressure so that it does not create gapping holes or destroying the whole side panel. Anyways, just my 0.2 cents... hope everything turns out well.

Mankz_91 · 06-28-2006, 06:07 PM

there is a much more simple and pleasing way---

cover the panel in sticky tape
drill a hole near a corner
Get out the Jigsaw
file of the end bits
re-paint the bare metal side with hobby pait.

theres something nice about cutting into bits of metal.....

B[x] · 06-28-2006, 06:48 PM

Quote:

Originally Posted by ChrisDVD

Here is a suggestions.....cut from the inside....somehow i would be scare to damamge the paint on the outside of the panel...

The stream of water is very fine so I'm not too worried about damaging the paint. If anything I think cutting from the outside would be better since I'd imagine cutting from the inside would cause paint to flake away. Worse comes to worse I'll repaint it.

Quote:

Originally Posted by P11

That sounds like a good idea...however, you have to take into consideration that the case is made out of very thin aluminum.

I read through this FAQ and found no reference to the minimum material thickness, only the maximum. If I can't get an answer by September I'll just ask the guy who runs the shop at my school.

Quote:

Originally Posted by Mankz_91

theres something nice about cutting into bits of metal.....

Jigsaws are not as accurate as a water jet cutter. Despite the nice fuzzy feeling you get when you make something with your hands, I would rather have the clean-cut appearance of smooth curves and straight lines.

B[x] · 06-29-2006, 06:30 AM

Alright, here's a preliminary layout that I had in mind and threw together over the past couple days, let me know what you guys think.
Just to clarify, the blue parts are the parts are cut out.

ChrisDVD · 06-29-2006, 05:03 PM

thats a cool design! Very stylish, out-of-this world, amazing, eye-catching, and original....
you still see your 'S', and yet, its seems like another shape.
Show us a pic once you will have done it!

06-28-2006, 04:42 PM	#1 (permalink)
B[x] New Member Join Date: Jun 2006 Location: Queens, NY Age: 22 Posts: 17	Water Jet Cutting a Case Window For my next build I want to take a standard case (something along the lines of the Lian Li PC-61) and cut my own window. I like the aforementioned case mainly because the side panels don't have any grills, fans, or other holes/ridges that would get in the way of a window. Also the inside of the case seems pretty open, thus allowing for a bigger window. The window I plan to make will be a custom design incorporating the letter S (my last name's first letter) in some way, shape, or form. My initial designs were relatively simply to allow for an easier time cutting. However, I then remembered that my school has a water jet cutter that I can more than likely use for this project. At this point the whole idea of keeping it simple went out the window (no pun intended) since water jet cutters can be extremely detailed - see here for some examples. I more than likely won't be using any window molding since some of the holes will more than likely be too small for it. For those of you that don't feel like reading up on it, these machines use a very fine stream of water (about 0.01" diameter) at absurdly high pressure (ranging from 20 to 60 ksi) to cut whatever material you need cut. They were originally designed to cut lumber but can now cut through anything ranging from fiberglass insulation to metal to food to concrete. Now, I've never used a water jet cutter before nor do I know the specs of mine such as whether it's pure water or abrasive. However, I don't think the specs would really matter seeing as how the material I will be cutting through won't be more than 1.0 mm thick. I'm wondering if anyone here has had experience with a water jet cutter whether it was used in modding a computer or not. I did a Search on these boards looking for people that made their own windows and I only came across one mention of using a water cutter but that's all it was, a mention. From what I understand you have to import a CAD file into the machine and then do some tweaks to line it up properly as well as show it which path you want it to cut. I am well versed with AutoCAD 2006 so desiging it isn't a problem, it's getting it from AutoCAD to the panel that I'm not sure of. I can easily obtain instruction once I get back to school but I'm really excited about the idea of using this process and wanted some input on it. Oh, on a little side note, the computer I'm running now isn't that old so I don't plan on actually doing this build for another year or so. Right now I'm just trying to figure out if this idea will work so that I can get serious about designing the window. I'll upload some pictures of some layouts I threw together when I get home from work. Last edited by B[x]; 06-28-2006 at 04:46 PM.

06-28-2006, 05:16 PM	#2 (permalink)
ChrisDVD Diamond Member Join Date: Apr 2006 Location: Canada Age: 18 Posts: 1,042	this sounds quite interessting. I was also thinking of cutting a window in my panel....but i never used a water jet cutter. It for sure would be better then using cutters Here is a suggestions.....cut from the inside....somehow i would be scare to damamge the paint on the outside of the panel... __________________ HP Pavillion a815n, 160 GB Hard Drive, 512 MB Ram, 16x DVD±RW DL Burner, Power suply- 300W Intel Pentium 4, 3.06 Ghz Power suply- 300W Mother board: ASUS PTGD1-LA Windows XP home Editions, Service Pack 2 Video Card: BFG GeForce FX 5500 oc 256 MB PCI HP Pavillion f1503 monitor HP Series 3 in 1 Printer Speakers: Logitech x-530 suround sound system 5.1

06-28-2006, 05:36 PM	#3 (permalink)
P11 VIP Member Join Date: Sep 2004 Location: Toronto Age: 19 Posts: 1,309	That sounds like a good idea...however, you have to take into consideration that the case is made out of very thin aluminum. I'm not too experienced with water jets but I could see a problem cutting the aluminum with high pressure water. There must be some type of adjustment to reduce water pressure so that it does not create gapping holes or destroying the whole side panel. Anyways, just my 0.2 cents... hope everything turns out well. __________________ Asus K8V-SE Deluxe AMD 64 3400+ 2.56 Ghz Cosair 1.5 GB PC-3200 400Mhz Enermax 535W/SLI-Ready/12V @38A 250GB Western Digital HD 8mb cache IDE 320GB Western Digital My Book Premium External HD Sony DVD+RW/+R Double Layer burner drive Logitech MX5000 Bluetooth Combo ATI X850XT 256MB ;) Diablotek Samurai ATX Case 3DMark03 PC Exposure : www.pcexposure.com

06-28-2006, 06:07 PM	#4 (permalink)
Mankz_91 Platinum Member Join Date: Feb 2006 Location: ......UK Age: 16 Posts: 534	there is a much more simple and pleasing way--- cover the panel in sticky tape drill a hole near a corner Get out the Jigsaw file of the end bits re-paint the bare metal side with hobby pait. theres something nice about cutting into bits of metal..... __________________ Project Watery Sponsored by...: HWLabs SpecialTech Feser 1

06-29-2006, 05:03 PM	#7 (permalink)
ChrisDVD Diamond Member Join Date: Apr 2006 Location: Canada Age: 18 Posts: 1,042	thats a cool design! Very stylish, out-of-this world, amazing, eye-catching, and original.... you still see your 'S', and yet, its seems like another shape. Show us a pic once you will have done it! __________________ HP Pavillion a815n, 160 GB Hard Drive, 512 MB Ram, 16x DVD±RW DL Burner, Power suply- 300W Intel Pentium 4, 3.06 Ghz Power suply- 300W Mother board: ASUS PTGD1-LA Windows XP home Editions, Service Pack 2 Video Card: BFG GeForce FX 5500 oc 256 MB PCI HP Pavillion f1503 monitor HP Series 3 in 1 Printer Speakers: Logitech x-530 suround sound system 5.1

06-29-2006, 06:30 AM	#6 (permalink)
B[x] New Member Join Date: Jun 2006 Location: Queens, NY Age: 22 Posts: 17	Alright, here's a preliminary layout that I had in mind and threw together over the past couple days, let me know what you guys think. Just to clarify, the blue parts are the parts are cut out.

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