Cutting the sides
The first step in the side panels was to tear out all of the sound deadening foam padding material. This went well until I got to their very strong and nasty double sticky tape, which took forever to get off. Once this was done though, I was left with a very nice and thick panel to cut the design into.
I decided to do the cutout first since that would help decide where the engraving would be able to go, and actually I was not very confident in my engraving skills (although I learned from the master engraver Wolverine). So, I took the cutout that I made for the mock up and traced the design onto the panel, which I covered in masking tape as to avoid ruining the brushed aluminium finish.
Even though I had to go to Belgium to find scroll saw blades (thanks Italy) I was able to cut through the side panels pretty easily with standard scroll saw blades using the saw that I purchased here for this purpose.
Once the cutting out was done, I used miniature files and four different grits of sandpaper to painstakingly remove the scratches and end up with a very smooth finish.
Once I was done with this, I cut out some red acrylic (graciously donated by my friend and fellow bit-tech
community member Rigormortem) and put this behind the cutout.
Adding the engravings
The next and harder task would be the engraving. This was really only harder because I have never really done it before. However, once I got started, it was actually much faster and easier than the cutouts.
I started by taking the full size drawings of the scary dudes and tracing their shape onto the aluminium using graphite paper (carbon paper). I then used the large ball diamond Dremel bit and traced the lines, filling in some areas where I would highlight more later.
Since the silver on silver colour is not ideal (and hardly readable) I chose to highlight the engravings with black marker (just like Wolverine does it) and the result I think is not bad for a first try. Of course if you want to know more about how to engrave anything from a case to your kitchen sink (not recommended but can be fun), you should check out Wolverine’s engraving article