How to Use a Dremel to Carve Aluminum

The Dremel rotary tool is the perfect choice for carving, cutting or otherwise modifying your aluminum computer case. The Dremel allows multiple attachments for maximum usability, while maintaining a small, easily maneuverable design. Depending on the task at hand, you might choose to cut out a panel, engrave a name or serial number, or polish away sharp edges.

• 1

  Draw a template on the aluminum case so that you are sure to cut to the proper dimensions. Do this by determining the dimensions you want to cut out and drawing the lines on the case.

• 2

  Unplug the Dremel rotary tool and attach the cutting disk. This is done by loosening the cottel nut at the tip of the Dremel, using the included wrench, and inserting the cutting disk attachment. Lock in place by tightening the cottel nut.

• 3

  Put on eye protection, ventilator and gloves to protect again flying debris and friction heat.

• 4

  Plug the Dremel back in and select your desired speed. Faster speeds cut faster, but slower speeds produce less heat and aid in precision. For aluminum, you can get by with slower speeds.

• 5

  Carve along the lines by holding the Dremel in a pencil-type grip and gently applying pressure. Cut a shallow groove all the way around and gradually increase depth on subsequent passes. Save any corners until you have cut all the way through the lines on either side of the corner. At that point, slide the disk as deep as you can into the cut groove and cut towards the corner. This will ensure square corners without cutting outside the lines. When everything is cut, remove the cut out piece.

• 6

  Exchange the tip to a honing stone, using the same procedure as before. Gently grind the cut edges until you remove and sharp edges or imperfections. You might need to change to a router or engraving attachment to fine-tune the corners. At this point, you are finished carving, but you may wish to repaint to cover any obvious cut areas.