ALIENWARE ALX Case Mod Project

Hi Everybody, Alienware featured my case mod project on their fanpage & Twitter and encouraged me to share it here. I did this mod in 2005 after buying the used ALX case on Ebay. The first ALX case I received had several plastic mounting tabs broken for the top and side panels. I had no way of replicating new plastic tabs, so this is the second, in much better condition with only these minor issues. 

1. Side panel latch cover sticks a bit, you have to press real firm to release it.
2. The back cover of the bay door had one broken plastic peg, but nothing detrimental.
4. The case feet are real scratched, but this is expected with plastic feet.
 
The ALX chassis was manufactured by Chenming, www.chenmingusa.com/Prototype.asp

 
Removing the Alienware's top plastic watercool radiator that enclosed Koolance EXOS radiator.

 Location of 2x 80mm cooling intake fans (not included) in Alienware's renewed cases. 

 
Behind the front bezel


 
I removed the center portions between the bars of the side panel vents. These will be sanded, and prepped for flat black paint.

Modders Mesh will be mounted behind the bars.

mnpctech.com/.../modders-mesh-honeycomb.html

  
What Alienware ALX case lacks, is a left side panel window. The ALX design incorporates a plastic shell over it's aluminum case panel. You must cut two windows in the panel in order to see inside of the case. This is a basic run through of what was involved in making the window.
 

 
You're limited on what you can design for a window without compromising how the plastic shell fastens onto the side panel. The reason is that theres several plastic tabs on it's backside of the plastic that clip onto the inner aluminum panel. You should draw your window design inside of these fasten tabs. You'll also notice the backside of the plastic is reinforced in which I can only describe as a grate.

To draw out your design, I'll use either 233+ 3M Green Masking Tape You can buy these Home Depot or Ace Hardware stores. You also apply tape so you don't scratch up the panel with the jigsaw's steel guard.

 


Dremel 1.5" Reinforced Oxide Cutting Wheels, mnpctech.com/.../cutting-wheels.html

 

 
Whenever I make a side panel window, I always use a jigsaw with a 18 TPI (teeth per inch) bi-metal cutting blade. I'll make the intial incision for the jigsaw blade with a rotary tool and 1.5" reinforced dremel cutting wheels

 
After your window is cut, you'll need to use a rounded side hand file to clean up the edges of you cut.

More to come soon!