Mnpctech has noticed several people from PC building community have asked what tools and materials they neccessary to install a custom window in an older PC case. This step-by-step guide by Mnpctech covers the basic process of cutting an aluminum or steel PC side access panel and installing a custom clear window.
Clear plastic sheets are available at most home-improvement stores. I’ve traditionally used 1/8-inch clear cast acrylic for my case windows, cutting it with a jigsaw or vertical band saw. Now, as an easier alternative to cut, you can use 1/16-inch clear LEXAN, which is flexible enough to cut by hand with heavy-duty tin / sheet-metal shears or scissors.
TOOLS & SUPPLIES NEEDED:
12" x 12" or 24" x 24" sheet of clear 1/16" LEXAN.
Blue Painters Tape.
Measuring Square / Ruler.
Dremel or Rotary Tool with Cutting Wheel.
Jigsaw with 18 TPI Bi-metal cutting blade.
Hand File.
Double-Sided Tape.
Here is the final results of the custom clear window installed in this guide.
Before you begin, wear eye protection and gloves when cutting or filing sheet metal. Keep sparks away from flammable materials and remove all metal filings before reinstalling the panel.
STEP 1: REMOVE AND MASK OFF THE PC PANEL:
Shut down and unplug the PC. Remove left-side access panel, place it on a stable work surface and cover the entire outside surface with overlapping strips of 2-inch-wide painter’s masking tape. The tape protects the paint or finish and provides a surface for marking the window.
STEP 2: MEASURE AND MARK:
Measure the available area carefully and mark the custom PC window location on the taped panel. Leave enough space around the opening for the panel frame, U-channel trim and adhesive tape. Double-check the measurements before cutting.
STEP 3: MAKE THE STARTER CUT IN THE PC PANEL:
Position the panel over a sturdy cardboard box. Wear eye protection and work gloves. Use a rotary tool equipped with a reinforced cutting wheel to make the initial opening inside the marked cut line.
STEP 4: CUTTING THE PC CUSTOM WINDOW MOD:
Insert an 18-TPI bi-metal jigsaw blade into the starter opening. Keep your jigsaw’s base plate flat against the panel and guide the blade slowly along the marked line. Let the blade do the cutting without forcing the tool.
STEP 5: DEBURR THE PC WINDOW EDGES:
After removing the center section of the custom pc window cut-out, use a hand file to remove sharp burrs and smooth the entire cut edge. Continue wearing gloves because freshly cut sheet metal can be extremely sharp.
STEP 6: INSTALL U-CHANNEL RUBBER EDGE TRIM:
Press on this
Mnpctech U-channel or similar rubber u-channel edge trim firmly over the metal edge of the window opening. Work gradually around each straight section and rounded corner until the entire opening is covered.
STEP 7: CUT THE 1/16-INCH LEXAN SHEET:
Measure and mark a clear window from a 24-by-24-inch sheet of 1/16-inch-thick Lexan. Make the window large enough to overlap the opening and adhesive area on every side. Cut it from the edge of the sheet using metal shear scissors.
TIP: You can use 1/8" thick cast acrylic sheet as substitute for 1/16" LEXAN sheet, but you must use Jigsaw to cut the cast acrylic.
STEP 8: APPLY DOUBLE-SIDED TAPE TO THE BACKSIDE OF PANEL:
Turn the PC side panel over and clean the mounting surface. Apply heavy-duty double-sided adhesive tape around the backside of the window opening, just outside the U-channel. Press the tape firmly against the panel and remove its red release backing.
STEP 9: ATTACH THE LEXAN (OR CAST ACRYLIC) CUSTOM PC WINDOW:
Remove the protective film from the mounting side of the Lexan window. Carefully align the clear window over the opening, lower it onto the exposed adhesive and press firmly around the entire perimeter.
SHOW-OFF YOUR WORK AND SHARE THIS GUIDE:
Reinstall the finished side panel and enjoy the transformation! Share this guide with anyone building a custom, retro or sleeper PC.
More PC builders are reviving old PC cases today. Many are installing custom clear windows in Dell OptiPlex desktop PCs, older HP towers and beige vintage PC cases to show off the hardware inside. Whether you’re building a sleeper gaming PC or restoring a retro computer, a DIY side panel window lets you keep that classic case and enjoy a view of your work. There’s something fun about an old office PC giving people a reason to stop and look.
Mnpctech has been inspiring custom PC case mods since 2001, and we hope this detailed window installation guide helps you tackle your own project. Take your time measuring, cutting and finishing the edges. That extra care shows in the finished panel. Visit Mnpctech’s online PC mod shop for window trim, custom case feet, fan grills and other PC modding supplies, and share your finished build with us. We’d love to see what’s hiding inside that beige box!
Mnpctech enjoys inspiring and educating PC case modders and supplying specialized PC-mod parts and accessories since 2001, including U-channel edge trim, billet-aluminum case feet, handles, fan grills, switches, acrylic panels, hardware and cooling accessories.
