Window Etching

Date: November 3, 2002
Author: Robert E. Bailey a.k.a.: RbReb13
Provided by: None
Time: Approximately 3 hours


 This is my first endeavor into case modding, other than cutting holes for fans. I will attempt to show how you can create your own etched window, with the use of basic tools and materials.
 First off I bought a case with a window already installed from Directron. It is an Aluminum case and was under $100.00 shipped.  More info here: http://store.yahoo.com/directron/8889al.html
 

After you have a window there are some basic materials and tools needed.

Tools and Materials:
1) Dremel Rotary Tool (I used a Model 395 Variable speed).
2) X-acto Knife (easiest) or single edge razor blade.
3) Masking tape (I used the 3M blue painters tape, it leaves no messy residue)
4) Sandpaper 220 grit
5) Tape measure or ruler.
6) Straight edge and protractor (I used what's called a French Curl).

First off you will need a template for the design you are going to use. The one I used was made by our Graphics Specialist, Iroc. Once you have decided on a design you'll need to tape it onto the window in the proper position for where you want the design. I taped mine on the outside as I wanted the scoring from the etching to be on the inside to reflect light better. My window came with protective sheeting on it for shipping. I left it on till I was done with all the modifications. You also will need a soft surface to work on. I used an old bath towel.

Ok, on to the actual work.
 

First off I highlighted the edges of my template with a Black Sharpie (used and dull). Then I taped it to the outside of my window after making some measurements to determine position. For mine I chose the exact center, yours may vary depending on the design.

Then I taped the template to the outside of the window.

After this it's just a matter of etching out the design. Having good light is essential for doing a good job. I also found that you need to work from right above the area to be etched. I made 2 passes with each bit, before I was satisfied with the end result. Also using both hands is a good idea as the tool tends to want to wander if you don't. I set my tool for approximately 30,000 rpm. This you will have to try for yourself to see what is comfortable for you. I started out by making two passes with a # 105 Dremel bit.

I then re-etched the design with a # 107 Dremel bit.

All this part was done with a Dremel Model #395.

After all the etching was done, I looked at it and didn't really like the way it looked. All of a sudden it came to me, Sandpaper. So I broke out the masking tape (3M Blue Painters type, no sticky mess and it comes off easily). I then masked off all the areas I didn't want sanded.
 
 

Using my X-acto knife I trimmed away all the tape that I didn't need for protection. I then used some 220 grit sandpaper and roughed the surface. This way I figured it would catch the light better. I was not disappointed.
Here are the final pictures for this project. I don't have a cold cathode yet, so I used my trouble light with a blue light bulb in it. This case is for a Dual Socket 370 system I am building. When it is done I will have a review and some final pictures. I will update this How-to when that is done. Have fun, I know I did.
 
 

Heres an updated pic with Cold Blue Cathode installed. And my Dual P-3 system up and running.