The plan originally called for using a plasma cutter to cut out a very deatiled window, but after a lot of thought I found that that a plasma cutter used by hand would be too much to handle, especially with protective glasses on. I decided to go for a simpler plan.

The first trick to pull off was getting the photoshopped picture onto the case side. To do this I printed out the picture full size and taped a piece of clear plastic sheet, actually the backing of a piece of monokote. Then I used a small knife to cut out the plastic to make a template of the printout that I could use for marking the case. After that, I taped the plastic to the case and used permanent marker to draw the design onto the case. Then I stuck masking tape over the whole thing and used a knife to cut out the tape as a further template.

I decided to use a small drill bit, #47 I think, to drill out the edges out the design, then go in with a dremel tool to rough it out with a cutoff wheel. After roughing it out, I'm going in with a whole bunch of files and filing it to the finished product.



You can see the steps of the process from bottom to top of the case becasue I have been working from top to bottom.

After getting some of it done I realized a huge mistake I made. I'm doing all the work on the exterior side, so I now have a ton of scratches and cutoff wheel marks on the exterior side.