Section 1- You will need…                                                                                                                                                                                           To cut a side window in a case, you will need the following items:

 

1-     A jigsaw and blades or rotary tool and cutting disks

2-     A drill and 5-10mm drill bit (only if using the jigsaw)

3-     A set of files

4-     A solid, flat surface (preferably 2 solid tables/workbenches, you will see why later)

5-     At least 4 clamps

6-     Some type of gloves (NOT the disposable rubber/latex)

7-     Safety goggles

 

Section 2- Jigsaw Vs rotary tool                                                                                                                          Either of these tools can be used, some people prefer the jigsaw because it is easier to control and some people say it creates less dust, however, some people prefer the rotary tool because they find it more comfortable to work with. Whichever tool you decide to use, you will need about 2-6 blades (depending on the quality of the blades, the size you want your window and the thickness of the metal) the average rotary tool cutting disks will last around 15-20cm cutting metal, some will last longer. I’m not sure about jigsaw blades, I would say get 3-4 although you may not need them all or you may need more, again, it depends on the quality of blades, thickness of metal and size of your desired window.

Which tool you use will depend on what you feel more comfortable using, for a 1^st time I would recommend the jigsaw, but again, its up to you. Also be aware to get “fine” or “extra fine” jigsaw blades for “thick metal”

 

Section 3- What surface?                                                                                                                                    This is not too important, as long as it is stable and supports both sides of the side panel (so you are cutting in the middle of 2 supports). Failing to support both sides could cause the metal to warp when cutting. I used a black&decker workmate for mine, although I did have to move the side panel around a lot as it is limited to how far it will open.

Section- 4 Clamping                                                                                                                                               All that I have to say about this is;

1-     make sure the side panel is well clamped

2-     if you are using clamps with metal ends and a small surface area (like g-clamps) make sure you put scrap wood or corrugated card in between the clamp and the side panel

 

Section 5- Why the gloves and goggles?                                                                                                                    The gloves and goggles are for your safety, tiny bits of metal could flick up and hit you in the face, it wouldn’t be nice to get one in your eye!

I got quite a few cuts on my hand when cutting my window (again, from the small bits of metal) I only put gloves on half way through.

 

 

Part B- The metal work                                                                                                      Start by planning where you would like to cut (draw it on the back in pencil and go over it with a marker when you are happy)

Section 7- The design                                                                                                                                         There are lots of designs for you to chose from, which one you decide to try should depend on your skill or experience and your imagination.

Some people like to do circles or squares because they are a simple shape, others prefer random shapes for various reasons; it is easier to cover up mistakes, they are more personal and they are interesting.

 

Part C- The window its self

 Section 9- The plastic

Section 9a- Perspex/Plexi glass

Either of  these can be used, there is not much difference between the 2, I am not going to comment on which is better because they are both suitable for the job (although Perspex is said to be more rigid)

Section 9b- What thickness?                                                                                                                                                                                     You now have the choice of what thickness to chose from, the common thicknesses are 1mm, 2mm, 3mm, 5mm and 10mm.

1mm and 2mm I would say is too thin but 10mm is too thick. I would recommend in between 3mm and 5mm

 

Section 9c- Cutting and other techniques (if required)                                                                                    To cut plastic, you can use a standard tennon saw or a coping saw (do not use thick/very jagged blades)

 If you would like a ‘frosted’ effect, get yourself a piece of wet and dry, cut it into a rectangle or square of such a size that you feel comfortable with, wet it under the tap or in a bucket of water and start sanding the surface of the plastic, I find it works out better if you make circular movements with the wet ‘n dry and just work your way from one side to the other, then flip it over and do the other side

If you would like to etch a design on, get your self an etching kit if you do not already have one, print a design or draw your own, temporarily stick it to the reverse of the plastic (do not use glue) all you need to do now it etch away... Simple!

 

Section 10- Attaching the plastic to the case                                                                                                    The best way to do this it to drill holes in the side panel, and then corresponding holes in the plastic, then bolt it on (you may need to cut the bolts to as short as possible for the side panel to fit on (in my case, a fan adaptor was in the way at the back)

 

All you need to do now is re-attach the side panel and you’re done!!!