A500 Case Mods

[Trev]

I need to cut a rectangular hole in an aging, slightly brittle A500 case, in the back next to the joystick ports. What's the best way to go about it without damaging the case? Dremel router bit? X-Acto knife? Soldering iron?

[-BobW-]

I've used a dremel to rough out the hole and then a flat file to clean it up.  If you take your time you will get a really nice result.  

http://deliriumbbs.freehostia.com/The_A1200CD_-_a_different_approach.bbs

Edit: Edited the link

[klx300r]

I've used a dremel to rough out the hole and then a flat file to clean it up.  If you take your time you will get a really nice result.  

http://deliriumbbs.freehostia.com/cms/pictures/1200cd/1200cdangle.jpg

+1 ...the trick is to be very patient and only use fine light strokes wiht the dremmel or you'll risk marring/burning the plastic

[Trev]

Thanks, guys. Looks like patience and a steady hand are the key then, regardless of the tool used. Maybe I'll have my wife do it. She's much handier with the Dremel than I am. :-P

[Crisisdog]

I need to cut a rectangular hole in an aging, slightly brittle A500 case, in the back next to the joystick ports. What's the best way to go about it without damaging the case? Dremel router bit? X-Acto knife? Soldering iron?

Hahahahaha!

I did use an old soldering iron to melt a semi-rectangular hole in the back of the case for a flicker fixer video port.  Cleaned it up with square corners using a flat file to make it look professional, , then superglued a trimmed down PC slot bracket with a VGA cutout already in place.  Looks like it was part of the original manufacturing process.  I would assume a series of drill bits to gradually increase the hole size could be used instead of the soldeing iron.  The plastic files away fairly easily to clean up the hole for more square corners.