Dremel Guide

Disclaimer : I will not be responsible if you damage your PC, chassis, hurt yourself or worst still, someone else, following my guide!! You do it at your own risk!!

Introduction
For a case mod freak, the Dremel is a very valuable tool to have. It lets you mutilate..... errr.......I mean modify your PC case in ways you have never dreamed possible. It is very easy to handle and it carries out it's intended purpose without much hassle. I know this, not only because I'm a mod freak, but also because I own one!!! I knew from the very moment I laid my eyes on this baby that I got to have it!!

You might be wondering what the hell is a Dremel and how it looks like. I knew you were gonna ask that so here are some pics of my Dremel. The one I got is the MultiPro version, which means that the spindle speed is adjustable from anything between 10,000 RPM to 37,000 RPM. It also has a power cord attached to it so you can plug it in into an electrical outlet.

The Dremel MultiPro Click to enlarge

The Carrying Case Click to enlarge

Inside the box Click to enlarge

Manuals and Accessories List Click to enlarge

It also came with a manual, an accessories list and 40 different kinds of accessories. In the picture below, you will notice the switch that is used to control the spindle speed of the Dremel. The Dremel utilizes a screw-on chuck together with the mandrel grip to secure the accessory in place.

Speed switch Click to enlarge

Screw-on chuck Click to enlarge

The mandrel grip
Click to enlarge

Scott of IPKOnfig also sends me his Dremel pics for comparison. I think his Dremel only has 2 speed settings and is battery operated. I have yet to see this model here in Singapore though.

Scott's Dremel Click to enlarge

Hey! His box is cooler than mine!!! Click to enlarge

Accessories
Click to enlarge

Mods Accessories
I mentioned earlier that the Dremel came with 40 different kind of accessories. I am not gonna mention them all but rather concentrate on the ones that will be used for the case mods operation. The circular ones you see below are the cut-off wheels, which are used for the actual cutting operation. The special mandrel for the wheels is shown at the top of the wheels.

Then there is the cylindrical, cone-shaped and round grinding wheels for metal workpiece which is useful for removing all the burrs on the edge of a freshly cut hole. A wire-brush attachment is also included for polishing the edges and a grinding wheel for wood/plastic, useful when you need to remove a lot of plastic mateial quickly (think front bezel mods!!).

The mods accessories!
Click to enlarge

Close-up of cut-off wheel Click to enlarge

See how thin this things are?? Click to enlarge

The cut-off wheels that came with the Dremel are a little bit too flimsy and thin. They break off easily during cutting and when too much force is applied to it. I would recommend getting some reinforced cut-off wheels for the cutting operation. As the name implies, the reinforced cut-off wheels are made of coarser material and embedded with a kind of wire mesh. It is this wire mesh that holds the so-called grit tightly together, and accounts for the extra strength and stability for heavy cutting.

Reinforced cut-off wheels Click to enlarge

Close-up showing the mesh Click to enlarge

Getting smaller after some heavy cutting ops!!!
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Accessories Attachment
Most of the accessories or cutting tools for the Dremel is attached to its' own mandrel, some removable for easy replacement of the cutting edges. The cut-off wheels utilizes a special mandrel with a small screw on top for securing the wheel. To secure the wheel, you need to remove the screw from the mandrel. Attached the screw to the middle of the wheel through a small hole in it and screw it back onto the mandrel.

Cut-off wheel mandrel Click to enlarge

Close up showing the screw Click to enlarge

The attached wheel
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To fix the wheel/mandrel attachment to the Dremel, you need to loosen the screw-on chuck and just slide the mandrel into the mandrel grip. Using the supplied wrench, tighten the chuck. The wheel is now ready for action! The same technique applies to all the other accessories.

Cut-off wheel mandrel attached to Dremel
Click to enlarge

OK! I know you can't wait to get to the actual cutting! So.....here we go!!!

Workpiece Preps
As for any cutting operation, you will need to prepare your workpiece first. You will need to mark out the outline and the position of the cut that you are about to make. For the circle, you can use many different tools like a round stencil or even the fan itself. I prefer to use the fan grill as the template.

For the purpose of this guide, the "victim" will be my new Enlight EN-7237 Mid ATX case. I will be cutting the following;

• 1 X 120mm hole on the side panel,
• 1 X 92mm hole at the top, and
• removing the grill at the 80mm fan mount at the back of the case.

If you're cutting anywhere on the case structure itself, make sure eveything that is removable IS REMOVED!! Electricity + Metal Shavings = DAMN F@#KING BAD!! You should also vacuum the case after that ops! Like I said, I used the grill to mark out the outline of the hole with a marker. You can use a pencil but the markings tends to fade away after a while.

92mm top hole Click to enlarge

120mm side hole Click to enlarge

80mm rear hole
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Safety Gears
You might also want to prepare some safety equipments for yourself. Hey! It doesn't hurt to be safe! First stop, safety glasses or goggles. Although the metal shavings would be very small, it can still get into your eyes if you're not careful. If you can afford it, get a face shield!!! You might want to wear gloves to protect your hands as the Dremel could get pretty hot spinning at 37,000 RPM!!! You might think that these apparels are not necessary, but prevention is sure damn better than spending some time in the hospital!!! Believe me, I have seen some pretty scary stuff in my 3 years as a Safety Officer!!

Safety glasses Click to enlarge

A pair of gloves Click to enlarge

Safety helmet?
Click to enlarge

How about a safety helmet??? OK! OK!! Sheesshh!!! I was only joking!!! :-D Let's get to the part you've been waiting for!!

Dremel Mayhem!!
I will be showing you how to cut the 92mm top hole first. The first thing you need to do is to drill the screw holes for the fans first. You can use a 5mm drill bit for this. Once that is done, check the holes alignment with the fan and the grill.

Screw holes drilled Click to enlarge

Checking alignment Click to enlarge

The curves, or circumference of the 92mm hole is quite tight so you might want to cut just a small portion at a time. I started out with a fresh cut-off wheel and let it cut just about half an inch of metal at a time. This will ensure that you stay on course and not stray away from the markings. Do not apply too much force. Just let the wheel slide across the workpiece, taking tiny bites. Continue to do so until finally the wheel cuts through the workpiece.

Preliminary cut Click to enlarge

Take small cuts. Click to enlarge

Wheel finally cuts through workpiece
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I strongly advise you to have somebody to take pictures for you!! I'm doing this with one hand holding the camera and the other on the Dremel!!! Hey, good help are hard to find!! Anyway, continue to work your way along the markings, taking small cuts at a time. Occasionally, you could stop to check the cut or just for a break, if you like!

You can clearly see the sparks here!! Click to enlarge

That's why you need safety glasses!! Click to enlarge

Before you take the final cut, make sure you hold the waste metal piece with one hand to ensure that the waste material does not fly off once the Dremel cuts through the hole. It hasn't happened to me yet, but I guess it doesn't hurt to just be on the safe side! You should get something like this once it's finished.

The hole almost done... Click to enlarge

VOILA!! Click to enlarge

Can you see the metal burrs??
Click to enlarge

Next up is the fan mount at the rear of the case. This cut is gonna be fairly easy as there is not much material to remove. You just need to cut the metal pieces that are holding the grill to the case structure. You should be able to finish this cut in a minute or two.

This is easy!! Click to enlarge

There! You're done! Click to enlarge

Once that is over, remove the cut-off wheel from the Dremel and attach the grinding wheel. You can use any of the wheels, but I'll be using the cone-shaped one. No particular reason for this. The wheel will be used to remove the metal burrs at the edges of the hole and to smoothen things out so that it does not cut your fingers! Then it's time to slap on da fans baby!!!

Grindging wheel attachment Click to enlarge

Finished holes Click to enlarge

Slap on da fans!!!
Click to enlarge

Dremel Mayhem Continues!!
Before we proceed to the last hole, you might want to slap on a fresh cut-off wheel to the Dremel. The last piece should have gotten smaller due to the friction on the first two cuts. This will also ensure you have a much better cut on the next hole.

Unlike a hole saw or jigsaw, you do not need to use some kind of clamps or jigs to hold down your workpiece when using the Dremel. This is due to the fact that the Dremel only takes small cuts at a time and the kick-back from the Dremel is very little. Try doing that with a hole saw or a jigsaw! I think you'll lose more than your ego!!!

Fresh cut-off wheel! Click to enlarge

No need for clamps here!! Click to enlarge

Getting back to the cut, this time we'll be cutting a120mm hole and the circumference of the hole is much larger so you can take a larger cut at a time. Start by drilling the screw holes first and then check their alignment with the fan and grill.

I then proceed to cut the hole out with a fresh cut-off wheel and let it cut about one and a half inches of metal at a time, an inch larger than the 92mm hole. Again, do not apply too much force and just let the wheel slide across the workpiece. Continue to do so until finally the wheel cuts through the workpiece.

You can take longer cuts here. Click to enlarge

I love those sparks!! Click to enlarge

About 1/3 left to cut.
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Working your way along the markings, you should be able to finish the hole in about 15-20 minutes. Change to the grinding wheel again and shave off all the sharp edges on the hole and you'll get something like this.

20 minutes! Not bad! Click to enlarge

Checking the alignments Click to enlarge

Slap on da fans!!!
Click to enlarge

Final Words
There you have it! All done with the help of the good 'ol Dremel! I'm not gonna explain why I chose the fan locations as they are, coz this is just not the place or guide!

As you can see, the Dremel truly is a Case Mod Freak dream tool! Well, at least to me! The cuts you see here are just some of the example of what the Dremel is capable of. And with all kinds of accessories that is available for the Dremel, its' use is only limited by your imaginations!

It's lightweight, easy to handle, have a whole range of accessories and is a much safer bet than the intimidating hole saws or jigsaws. If you're a mod freak, or a mod freak wannabe, then the Dremel could make your mods a whole lot easier!!! For more information on the Dremel, please visit their website at http://www.dremel.com. (Yucks!! I sound like a TV Commercial!!)

As usual, any comments, please mail me!!