How to Cut a Side Panel Window

Turn off and unplug your computer. Touch a large metal surface to discharge any static electricity from your body before touching the case. Remove the screws securing the panel to the side of the computer case, using a Phillips screwdriver. Slide the panel off by pushing it toward the back of the case rear and then pulling it away. Set the panel on a flat work surface

Cover both sides of the panel with masking tape to avoid scratching the surface of the panel as you cut. Draw an outline of the panel window that you wish to cut. Panel windows can be any size or shape on the panel, as well as any design. When making complicated shapes, make certain that the entire shape is supported by a connection to the panel. For example, to create a circle that still has a panel piece in its interior; you’ll need to leave a portion of the circle’s edge uncut to allow for a connection between the interior piece of panel and the exterior piece. Make certain that your lines are placed so that you have one or more cutouts that you can remove in single pieces.

Measure the length and width of the panel. Cut a piece of particleboard with a circular saw to place beneath the rear of the panel to keep the panel from flexing as you make your cut. A flexing panel leads to a jagged cut edge.

Tape the particleboard in place with strips of double-sided tape.

Put on a pair of work gloves and safety goggles for protection from any metal or plastic shards from your case panel.

Attach a cutoff wheel to a rotary tool. Turn on the tool, then cut along the marked line with the wheel to cut through the case.

Pull the cutouts free to reveal the rough edges of your window panel. Remove the particleboard from the back of the panel.

Remove the cutoff wheel from the rotary tool and replace it with a grinding wheel. Turn on the tool and run the grinding wheel over the edges of the cut to smooth them out. This will remove any jagged edges created during the cutting process.

Place a thin piece of flexible rubber trim along the edge of the panel window to cover the cut edges. Use trim that's the same color as the panel to avoid having it stand out. Slide the two sides of the trim over the cut edge, following the path of the cutout until all of the edges are covered. Cut the trim to fit using a utility knife.