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How to cut and modify a computer case fast with a plasma cutter
Short answer: the fastest way I found to cut and modify a computer case is a plasma cutter. Clamp the ground cable to the chassis, put a piece of metal under the work to protect your table, lift the torch, press the button and cut. On a computer you care about, remove the motherboard, drives and anything fragile first.
In this short video I cut the front of a case so the hard drives slide out the front instead of hitting the RAM and CPU heatsink.
The problem: drives blocked by RAM and heatsink
I wanted to remove the hard drives from this case, but the RAM blocked them from coming all the way out. Even without the RAM, the CPU heatsink was in the way, and I didn’t want to pull the motherboard and everything just to remove a drive.
So the solution was to cut the case so the drives can come out through the front — and it was a perfect excuse to show how easy a case mod can be.
The tool: Hypertherm plasma cutter
I use a Hypertherm plasma cutter, the best brand I have tested so far. With it you can cut almost anything. It works a bit like a welder: there are two cables, and the ground cable connects to the chassis.
To cut, lift the torch, push the button and start cutting along the line you want. I have another video on how to use this tool in more detail.
Protect your table and do the cut
Before you cut anything, put a piece of metal underneath. That way if a big, hot piece of metal flies off, it won’t damage your table.
I cut the front section so the drives can be pulled out forward. On this case the front cover had no screws — it just pulls off.
Results: drives out, PC still works
The drives came out very easily. They burned a little, but in this case I didn’t care about those drives. After the cut everything was up and running: the motherboard wasn’t damaged by the sparks, the PC posted, the screen and video card worked and everything else seemed fine.
Now, in the future, removing a drive is quick.
Should you do this with components inside?
I would not recommend it on a computer you care about, even though mine worked fine. If the drives have important data, don’t cut with them inside. On an important computer, remove the whole motherboard and everything fragile, including the drives, do the cutting, then put everything back in.
Frequently asked questions
What tool is fastest to cut a computer case?
A plasma cutter. I use a Hypertherm: clamp the ground to the chassis, lift the torch, press the button and cut.
Can I cut the case with the computer parts still inside?
I did it and the PC still worked, but I don’t recommend it. The drives burned a little. On a computer you care about, remove the motherboard, drives and anything fragile first.
How do I protect my work surface?
Put a piece of metal under the case before cutting so hot pieces of metal don’t damage the table.
Why modify the case?
The drives couldn’t come out past the RAM and CPU heatsink. Cutting the front lets them slide out without removing the motherboard.