Windows 7: couching up paint after window installation

i want to use a jig saw to cut out a window in the side of my phantom, the hole will be where the 230mm goes. i wont be able to get c chanel to fit because the angles are very abrupt, 90, 90, 45, and 135 degrees. the edges will be rounded, but not more than about 1/4-3/4 of an inch. if anyone knows how i could still make this look good, paint the edges or something, and tell me how i would do it and what materials i would need i would appreciate it

I have seen mods where the modder used a Dremel with a fine grinding stone to round the sharp metal edges and refine the outline of the cut to get it perfect. A hand file would do it too but is labor intensive and edge support is needed. Paint the final result and it won't need a C-channel but will look factory done.

honestly i would like c channel, however, like i said, those angles are tricky. if you or anyone else knows what i might be able to do to still use c channel i would appreciate it

One option is to drill a hole where the corner will be, then cut your line to line up with the hole so you end up with a round corner. Another option is to use a round file to make the corners rounded. Then you can use your c channel. IMHO a Dremel tool is the way to go. Thats what I use to cut out the factory fan grills in my cases for more air flow. It took some practice but cutting round holes doesn't scare me anymore. Masking tape will help you minimize scratches too.

C-channel might work if there are relief cuts in it on the outside of the radii of the corners, but may not look real nice.

Hello there. Look at this video, and it will teach you how to do a hole in the case with a dremel...

thank you for the link, but it really doesnt answer my question, but it does boost my confidence in my abilities with a dremel. however im not suer i will use a dremmel or a cutoff whele on an angle grinder. but ultimatly i like the idea of just hacking the two edges of the c chanel so it bends at odd angles

why not just take the mesh out and cut some perspex to fit? youll see all the good bits even with a window that size.

well i dont want to JUST take the mesh out cuz it cas holes drilled INTO THE CASE for a 230/250mm fan, plus i dont want just a circle