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The "theme" of this case will be a Digimon. Originally it was going to be a yellow case with a Pokemon character on it but my daughter's tastes have changed. | Anyway after surfing Digimon sites on the net (and what a nightmare that turned out to be - more popups than most warez or pr0n sites), I found this image of a "Digivice".
So the plan is to cut this pattern from vinyl adhesive (same material as pin-striping on cars) for the left side of the case. A ducted fan will go where the circle in the bottom of the device is and a window where the screen is.
In this image you can kind of see the pencil marks showing the rough sketch of where the "Digivice" will be. I have already cut out the fan hole and am making a pilot hole for the jigsaw blade.
And here is the window being cut.
The jigsaw is the perfect tool for this type of job. With a fine-toothed sawblade the hole was cut quickly and came out almost perfect. I did deburr the edges a bit but overall I was not too concerned about them being ruler-straight since I will be putting a trim around the window later.
OK, now I have a slight problem with those vents. They will serve no purpose and will be visually distracting (not to mention making putting the decal on difficult). So a little bondo will do the trick.
I filled them in, let it dry and then sanded the filler down. This process was repeated a couple times to get rid of all the air pockets in the bondo.
I didn't take any pics but I next used the JB Weld to fasten some more bolts for this side intake fan.
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