Got a New Case!

Thanks, NoN! I already have some rubber molding on order. Hopefully, it will arrive at my mail service tomorrow; I'll pick it up then or Tuesday, depending on when another order is due to arrive. As I mentioned in my last post, I cut the hole a bit too small and will have to make it bigger so I need to wait until the molding arrives to see how much I need to cut out. If I can find a longer cutting bit for my Dremel circle cutter (over half the time on the first hole was spent rechucking the bit because it was a bit too short for the collet to get a proper grip on it), I might be able to fasten a piece of wood under the hole, using the fan screw mounting holes and drill a pivot point for the circle cutter. Otherwise, it will take one or more cutoff wheels and a lot of nerve wracking time to manually cut the hole out.

Jeannie one of Dremel's grinding wheel may work out since you have a small amount to take off. It's much faster and the don't fly apart like the cut-off wheels do. They can also make the edge quite smooth saving sanding or filing.

Britton30 said:

Jeannie one of Dremel's grinding wheel may work out since you have a small amount to take off. It's much faster and the don't fly apart like the cut-off wheels do. They can also make the edge quite smooth saving sanding or filing.

It all depends on how much I need to take off, which I won't know until I get the molding and see exactly how much I need to take off. If all I need is a gentle trim, the circle cutting jig will be easier and faster than having to lay out a circle and sneak up to it with the grinder. If I have to go all the way to the point where the raised lip starts, I might be better off using the wheel to remove most of it, then clean it up with the circle cutting jig.

I've been lucky; I haven't had a cutoff wheel fly apart on my yet. The trick on sheet metal is to take short shallow cuts, using a gentle feed, and gradually deepen them until the wheel just breaks through. That avoids binding which is what breaks wheels. The thing I don't like about cutting wheels anymore is it takes steady hands and a good grip. I can't maintain that grip for very long anymore because the arthritis in my hands and wrists flares up if I push them too hard for more than a short time.

Talking about Dremel tools, I spent much of today using mine and I'm paying for it now. My left hand and right foot are cramping. The hand is cramping from using it to guide the Dremel. I hold the body in my right hand and use the forefinger and thumb on my left hand (the thumb that is getting arthritis pretty bad, of course) on the nose to guide it. I have no clue why the right foot decided to start cramping other than I have had a lot of problems with leg cramps due to muscle damage from taking Zocor a few years ago. I have problems with low sodium levels which can cause muscle cramps so I drank a glass of salt water; that often helps.

I cut out the rear 120mm fan grill to make room for a 140mm fan. I didn't worry too much about making it pretty because it will be covered on the outside with an aluminum fan grill and on the inside with acoustic foam. I also wanted to leave as much metal as possible to avoid weakening the case too much. I also had to make a couple of dimples in the back of the aluminum fan grill to clear the heads of a couple of %$#@! rivets that were otherwise in the way. I still have to cut the center "bull's eye" from the grill since it won't keep my fingers out of the fan (and I bleed profusely) and would look dorky with a wire grill over it. I'll use the same wire grill over the rear fan as the ones that will go over the top fans. I did get one break; I had thought I was going to have to shave a bit from two of the sides of the aluminum fan grill but it fits perfectly. Thank you, God!

I finally figured out why Corsair put those holes there. The same case, without side panels, is also used with the 600T. The 600t has a different front panel that snaps on the front of the case but uses the same holes the 650D uses. The 600T also has a back panel that snaps on the back; that's what those extra holes on the back panel are for. The 600T also has a bottom panel that snaps onto the bottom of the case and has its own feet instead of separate feet like the 650D has. There is also an added top panel that apparently snaps into the tops of the front and back panels. Basically, the 600t is a plastic case wrapped around the metal case of the 650D.

Some of the holes in the case are roughly 5/16" guide holes for plastic dowels on the panels to help keep the panels properly aligned. I decided to use the same kind of plug I got to fill the two grommet holes on the back of the case to fill the smaller holes on the back and bottom of the case. Since those holes have a deep flange on them and the smallest plugs I could get are 3/8", I drilled out the holes to 3/8", taking the flange out with them (I finally got to play with my new right angle drill!). I remembered a trick my Daddy taught me (he was a machinist) to keep large drill bits from snagging when breaking through. He taught me to put a piece of paper towel folded into several layers between the bit and the metal. Works like a charm. I wish Daddy was still around to help me with this project. He would have had a ball.

No pictures today since there is nothing spectacular about a bunch of holes. I still have that front fan hole to redo (I'm not looking forward to that), the fan grill center that has to be removed (I'm not looking forward to that either), and the center tab on the left bottom side of the case that helps to align the left side panel but gets in the way of removing the bottom HDD tray from the third HDD cage (whoever designed that should be horsewhipped; fortunately, the side panel will still be aligned by the remaining two tabs). I also need to cut some tabs off the third HDD cage, cut the top off the extra HDD cage I got just for the piece I will be cutting off, shorten and slightly relocate the base for the two front HDD cages, and cut out the grill for the PSU air supply. The job I'm really dreading is fabricating a top plate to replace the mesh that is there now

For the cramps, which I have too at times, drink plenty of water, muscles get dehydrated which makes them cramp. Calcium helps too, I take it daily. Women need it more than men and it helps with oxygen absorption in the blood.

Thanks for the tips. I drink like a fish (keep in mind fish don't swim in alcohol ) and my blood calcium levels have always checked out OK (I get tested twice yearly). However, I take a prescription diuretic that excretes sodium as well as water but spares potassium (another element that can cause muscle cramps when deficient). Since I don't like salty food, I have to really watch my sodium intake to make sure I'm getting enough. Every once in a while, despite having "normally" high potassium levels, my potassium levels will slip and salt alone won't help me any. On those occasions, I resort to chugging a bottle of PowerAde Zero (the only sports drink I've found that doesn't have sugar—I'm on a low sugar diet) with some salt added. Eating a banana would also help raise my potassium levels but I can't stand them; the smell alone makes me want to hurl!

I'm not going to get much done today. The cramps are gone and I was able to get a decent night's sleep but it's windy outside and my allergies are already driving me 'round the bend (no short trip cracks please) so I'll probably just chill today.

Stepping back for some meditation is always a good idea. Crap, once I had a dream about how to fix a problem I was having and it worked.

I have to take frequent breaks when I'm working on a project like this since mental stress can manifest physically in addition to being physically handicapped already. It took me all day to do a project that should have taken only three hours 10-15 years ago.

I keep a note pad and a pen on the night stand by my bed because I occasionally get ideas during the night. Meditation doesn't work for me because my mind wanders too much and I distract easily (ADHD). However, switching to a different, less stressful activity, such as watching a pleasant TV show (rare anymore) or movie, reading, or listening to relaxing music helps considerably. I usually read for a while before going to sleep at night because it helps to pull my mind from the day's activities.

I used mediation as a misnomer. What I meant was just doing something else for awhile, something I have a hard time doing, I gotta get this done! mentality. I have too much attention.

I know that "gotta get 'er done RIGHT NOW!" feeling. Retirement has gone a long way toward reducing that emotion.