Part Three: Cutting And Mounting
How the case is altered to attach the components to it.
This was the fun part! I got to destroy and cut things until the case was the way I wanted it. This part also took the longest to do.
Attaching the Backplate
Measure the backplate, and use a utility knife to mark its INTERIOR dimensions on the side of the case opposite the wheels. (The interior being the part that sticks inside the case.)
Using the straight carbide cutter, remove the material within the marks you just made. Hint: Stay well inside the lines! This should be a tight fit. Use a flathead screwdriver to pry stubborn material out.
Dry-fit the backplate into the hole, noting where the hole needed to be altered to fit it perfectly.
Remove the backplate and use the silicon carbide sanding drums to remove any excess material.
Dry-fit the backplate again, and repeat steps 4 and 5 as needed until it is a perfect fit.
Use the steel wire brush attachment to smooth out the edges.
Put the backplate in place, then use a small screw to poke through the holes where the rivets were to mark where you need to drill holes to attach it with bolts. These holes should be 1/8" wide (Make them that wide if they aren't by using the 1/8" drill bit). NOTE: Only mount the backplate on the bottom of the case!
Remove the backplate, and use the 1/8" drill bit to drill holes through the case where the bolts will go through.
Put the backplate on again, push the bolts through the holes (from the outside. Stubborn ones can be turned with a screwdriver.), and bolt the plate on.
Cut any excess off of the bolts with heavy-gauge wire cutters.
Your case should now look something like this. (Outside view)
Attaching the Motherboard Mounting Plate
The mounting plate should have places to attach it to the backplate you just installed. Dry fit it to ensure it fits correctly in the case.
If the motherboard and backplate don't fit together well, STOP... remove the backplate, and make alterations to the case using a silicon carbide sanding drum. Otherwise, continue...
Level the motherboard mounting plate relative to the bottom of the case. (Stack shims under it or anything else that's handy.) Note how many nuts it takes to fill that space when they are stacked atop each other.
Find NO LESS THAN FOUR places that bolts going through the bottom of the case can go through the mounting plate to attach it with nuts. Mark those places and remove the mounting plate.
Use the 1/8" drill bit to drill holes at the places you marked.
Put the bolts through the holes. (From the outside.)
Put the number of nuts you found in step 3 on the bolts, and tighten them down loosely.
Put the motherboard mounting plate into the case (sliding or screwing the bolts all the way through it as much as possible).
Use one nut per bolt to firmly attach the plate. Tighten the bolts completely.
Note the distance the bolts push through the plate, cut any excess down to 1/8" maximum.
Attach your motherboard to the mounting plate. MAKE SURE IT DOES NOT CONTACT ANY BOLTS OR NUTS!
Some pictures to help you: Bolts going through case. Mounting plate attached!
Attaching the Power Supply
The power supply is mounted inside the back of the case (opposite the handle). Find a place where the power supply:
Has contact with the motherboard plate (not with the motherboard itself!)
Fan can exhaust air outside of the case when a hole is cut.
Any holes cut will not structurally impair the case (go through hinges or anything like that).
On the inside of the case, mark where there are 1/8" screw holes below the fan on the bottom corners of the power supply (on the side the fan faces out of). Almost all power supplies have screw holes there.
Using the 1/8" drill bit, drill holes from the INSIDE of the case, through the marks you made.
Take the top off of your power supply! Unscrew and raise the board inside so that you can get to the bottom of it.
Push the bolts through the holes you drilled in the back. Attach the power supply (even though no hole has been cut for the fan or for cords!).
Using the 1/8" drill bit, drill a hole through the bottom of the power supply on the side opposite the fan, drilling through the motherboard plate and the bottom of the case in the process.
Note where the fan and any cord inputs and switches are on the back of your power supply. Detach the power supply and mark inside the case where a single hole can be cut that accommodates the fan, any power cords, and any switches. Make sure to stay clear (at least 1/2" away) of the bolt holes that attach it.
Use the straight carbide cutter from inside the case to remove material that is inside your markings.
Use the sander to fine-tune any cuts you make.
Use the steel wire brush to clean up the edges.
Attach the power supply through the bolt holes in the back and the single bolt hole in the bottom of the case (that one with a nut). Ensure that no bolts touch ANY of the components inside the power supply. Cut off any excess.
Leave the top to the power supply off, and the board inside detached.
Your case should now look a lot like this.
Attaching the Drive Bracket
You're almost there! Keep going!
The drive bracket will be attached like this. Here is a picture of the finished product to give you a better idea.
Place the drive bracket inside the case where you need it to be attached. Note that the case must be able to swing closed fully!
Mark the places where bolts can attach the front of the bracket.
Remove the bracket and drill (from the inside to the outside) holes for the places you marked using the 1/8" drill bit.
Attach the bracket using 1/8" nuts and bolts (nuts on the inside as always). Cut off any excess.
With the bracket still mounted, use the straight carbide cutter to poke through the case (from the outside to the inside) at the corners of your brackets. You can also use the 1/8" drill bit for this if you want.
On the outside of the case, mark straight lines between the holes you've made with a utility knife.
Use the straight carbide cutter to remove the material within your marks.
Use the silicon carbide sanding drums to fine-tune the hole you made.
Use the steel wire brush to clean up the edges.
Once you're done with this, you can put away your tools and eye protection and proceed to disassembly, clean-up, and final assembly!!!
