Modding Tools
April 23rd, 2004


Written By: Rich "DickNervous" Neves

with contributions from: Skyler "Sky" Salmasi

Edited By: John "GruntmaN" Krump

Cutting Tools


Basically a tool that you can use to cut your case would fall into this category and while there are many tools out there that can do that, we will focus on the most common ones.

 


Utility Knife

Utility Knife: Simple, yet effective. The utility knife is a universal tool that everyone should have, Useful for opening the boxes of modding supplies you get from your favorite vendor, cutting sandpaper, slicing wires, and taking off bits of skin. So be careful with it.


Nibbler


Close up of business end of nibbler

The nibbler is a hand tool that is used to cut through the metal panels of a case. You use it by first drilling a hold in the case and then inserting the nibbler into the hole and squeezing it. It will then “nibble” off a small piece of metal. You then clear the metal away when it builds up and re-position the nibbler for the next piece. This is a very cumbersome way to cut a case, but with a price tag of about $10 and something that makes almost no noise, it can be handy, even if very slow. If you must use a nibbler, try to either find one with padded handles or wear work gloves when using it. It's also best to buy a high-quality nibbler as some of the cheaper ones don't last too long.

When using a nibbler you will usually need to clean up the cuts with some files or a rotary tool afterwards as the edges will not be smooth. Nibblers are good for small cutting jobs and some detail work, it really depends upon how detailed you want to get.


Cordless 2 Speed and corded 10 speed rotary tools

Rotary Tool (Dremel): We will call these Dremels from now on, but keep in mind that there are several brands of rotary tools, most common of which are Dremel and Craftsman. Rotary tools can be divided into 3 categories: Cordless, low speed, and high speed. What makes a Dremel so versatile and the tool of choice is the seemingly endless variety of the bits that can be used in it for everything from cutting to engraving to polishing.


•  Cordless Dremels are very handy for small jobs where a lot of power is not needed such as etching acrylic or polishing edges. They are generally lighter then their corded cousins due to the fact that they don't have nearly as big a motor.

•  Low Speed Dremels usually come with 2 speeds and hit about 10,000 rpms.

•  High Speed Dremels usually come with 8-10 speeds ranging from 2,000rpms to 35,000rpms. These are the most common type used by modders.

I highly recommend a variable speed Dremel. There is nothing worse then cutting Plexi at 10000 rpms and having no control over the speed. Variable speeds help control the dremel, the metal and the precise cuts by hand.

 

Obviously Dremel is the brand of choice here, but Craftsman makes a good tool as well; especially since it is simply a Dremel that has a Craftsman logo on it. We will discuss in more detail the different bits for the Dremel, but keep in mind that generally the Dremel brand bits and cut off discs are actually better then the other brands.

 


Dremel Drill Press
Dremels can essentially be used for almost any task. Need to cut steel, aluminum, or plastic. Use a Dremel with a cut off wheel. Want to clean the edges of a cut: Dremel with grinding stone or sanding disc. Need to polish some acrylic edges: Dremel with polishing wheel. Want to etch something into acrylic, or even metal: Dremel with engraving bit. You get the picture yet?

In addition to all the bits there are accessories for the Dremel that turn it into a mini-drill press, plunge router, circle cutter, and even a small table router.


Dremel Advantage

Rotary Saw: A rotary saw works on many of the same principles of the rotary tool but is designed differently. Originally designed for cutting drywall and tile, they have become adept at performing all types of tasks with the right attachments. The most common brands are the Bosch Rotozip, Dremel Advantage, and Craftsman. Some, like the Dremel Advantage come with attachments that allow you to use regular Dremel bits as well. These tools are ideal for cutting acrylic and can be used for cutting your case as well.


Plunge Router and Flex-Shaft Attachements for Dremel Advantage

In a similar fashion as the Dremel rotary tools, there are many attachments for the rotary saw to make it behave like a router, saw or drill.


Jigsaw

Jigsaw: Jigsaws have been around for a long time and are a favorite power tool for woodworkers due to their ability to make quick clean cuts in materials and be able to get some detail and shape in the cut. With the use of metal blades they become very good for cutting windows in a case. For the most part, and the amount of use a jigsaw will get in your case modding, any brand will do. Just makes sure you get good blades. I can attest to the fact that the better jigsaws make much cleaner cuts.

 

Typically you would use a jigsaw for larger cuts, like full windows in the side or top of a case. You can also use a jigsaw for cutting acrylic sheets down to a more manageable size. The most important thing with a jigsaw is to make sure you use good quality sharp blades. This will make cutting any material a breeze.


Craftsman Corded Drill


120mm Hole Saw with bit

Drill/Holesaw: No workshop should be without a good power drill. Corded drills provide all the torque you will ever need when working on your case, but cordless drills provide freedom and ease of use. When combined with a Holesaw a drill becomes a modder's 2 nd favorite tool. A Holesaw is basically a large round drill bit that cuts holes in materials. These are perfect for cutting fan holes since they will be the same size and perfectly round every time. However, you need a drill with a lot of power to use them, so if you have a weak cordless drill, it won't work


76mm, 81mm, 89mm, 92mm, 120mm Hole Saws and bit


Unibit

In addition to a Holesaw, the second most popular bit any modder will use is something called a Unibit. This is a cone-shaped bit which looks like a rounded pyramid. Each “step” on the bit is a size bigger then the one before it. So the deeper you push the bit, the bigger the hole it will drill. This is a great tool for drilling holes in acrylic as it doesn't have the tendency of regular drill bits to “pull” the acrylic up and crack it.

Makita 18.2v Cordless Drill

If you are looking to purchase a corded drill, most brands will be just fine. Craftsman makes great tools all around and we would not hesitate suggesting you pick one up. Make sure the drill has at least two speeds and a good deal of torque. On the cordless side you would be well served sticking with the high-power (over 14.4 volts) name brands such as Makita, DeWalt, and Milwaukee. We've also had great luck with the higher-end Black and Decker models over 18v which offer a very appealing price tag.


Milwaulkee Heat Gun

Heat Gun: A what? Yes, a heat gun. Think of it as a blow dryer on steroids. Heat guns come in very handy for bending and shaping acrylic the way you want and for shrinking heat shrink. Just be careful, they do get hot.

 
Next >>>>
CONTENTS
Page 1: Introduction
Page 2: Brands
Page 3: Basic Tools
Page 4: Cutting Tools
Page 5: Finishing Tools
Page 6: Dremel Bits


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