Planning to make my custom case.

[gertsy]

Looks like a great option, Vs starting from scratch.

[gertsy]

Finally I fixed the floppy today; not it is nice and snuggle inside the case.

The metal is pretty soft; tried to use a filer to smooth the opening but the whole thing would warp; I just gave up the idea to smooth it, nobody will touch the inside so it is good as is, and in the front you will not see anything, since the front plate covers it.

Tomorrow I will put the motherboard back in, and fix the wood base to the bottom of the case (need long nuts and bolts; the ones that I have are not long enough); then it is just a matter of finishing the front plate (found a nice tutorial about case mods, that uses fiberglass epoxy...few coats of that, sand it down and paint and the panel will look pretty much as original.

You will want to make sure at a minimum that you get rid of any loose edges and shavings. Very dangerous to your electronics if they end up on the motherboard.

A hand grinder will do the job.

[gertsy]

A magnet wrapped in cling wrap will pick up those metal filings cleanly.