I‘m modifying a computer case for my brother. We are discussing several mounting options and are needed to find a way to easily and precisely cut the sheet metal of the case. And inexpensive too if possible (under $100). We need to be able to cut out precise squares without damaging the metal around. For cutting out circles, we have figured on wood/metal holes saws.
Try locking the doors, unlocking the passenger door, or the trunk.
You can get a cutting disk for a drill motor to cut with. Tape off the entire area first with masking tape, draw your outline, then cut.
If you have only a few to do a nibbler tool will work. They are available at RadioShack. They cut clean but are a bit slow. For round holes a chassis punch works better than a hole saw. They are available in sets for smaller sizes at a reasonable price, Larger sizes get rather expensive. These are the tools that ham radio and electronic experimenters have used for decades. They work well with nice clean results. A dremel tool will work but don't expect to get professional looking results.
Find any asbestos in your Eureka Ez Clean vacuum lately? have another look behind the hepa filter. It says referb and then has a sticker on it wonder why containers are coming from East with asbestos plates inside and shiny stickers outside? Take your project to a sheetmetal place and they will probably cut it out for free for you if you buy the metal there. Make it out of copper it would be freaky cool. Did I tell you I found 2 pieces of Asbestos type material in my Eureka Vacuum I bought. Pretty odd, going to get them tested for sure!
