This is DIY Case Mod Guide for modifying your Corsair 350, 750 & 900D Front Air Intake Grill to help improve airflow to your Liquid or Aircooled PC system
Tools & Supplies:
Modder's Mesh, Round Sheet,http://mnpctech.com/case-mods-gaming-pc-liquid-modding-custom-computer-mnpctech-overclock-cooling-fan-grills/modders-mesh-perforated-aluminum-steel-honeycomb-grill-intake-front-fan-slotted-diamond-round-hex/modders-mesh.html

In Order of Usage
1. Ruler or Measuring Combination Square,
http://www.amazon.com/Empire-Level-E250-Professional-Combination/dp/B000ETUNEU/ref=sr_1_2?s=hi&ie=UTF8&qid=1371561237&sr=1-2&keywords=measuring+square
*2. Pen & Black Marker,
http://www.amazon.com/Sharpie-30001EA-Permanent-Marker-Black-SAN30001EA/dp/B00584PWWO/ref=sr_1_2?s=hi&ie=UTF8&qid=1371565029&sr=1-2&keywords=sharpie+black
3. Phillips Screw Driver,
http://www.amazon.com/STANLEY-TOOLS-68-012-All-in-One-Screwdriver/dp/B00009V431/ref=sr_1_1?s=hi&ie=UTF8&qid=1371561308&sr=1-1&keywords=phillips+screwdriver
4. 3" Painter's Masking Tape,
http://mnpctech.com/case-...masking-tape-roll.html
5. Safety Glasses,
http://www.mnpctech.com/Safetyglasses.html
6. Rotary Tool,
http://www.amazon.com/Black-Decker-RTX-6-3-Speed-Accessories/dp/B0001GUDRI
7. Rotary*1.5" Cutting Wheel,http://www.mnpctech.com/DremelDisc.html
8. Jigsaw Power Tool,
http://www.amazon.com/s/ref=nb_sb_noss?url=node%3D552934&field-keywords=jigsaw
9. 18 TPI bi-metal Jigsaw blade,
http://www.amazon.com/Bosch-T118EF-Bi-Metal-Shank-Jigsaw/dp/B000628CZ2/ref=sr_1_2?s=hi&ie=UTF8&qid=1371558431&sr=1-2&keywords=jigsaw+18+tpi+blade
10. Hand File,
http://www.amazon.com/Nicholson-06601-8-Inch-Handy-File/dp/B00002N7RN/ref=sr_1_6?s=hi&ie=UTF8&qid=1371558465&sr=1-6&keywords=hand+file
11. Blue Painter's Tape, 1" wide,
http://www.amazon.com/ScotchBlue-Painters-Multi-Surface-70-Inch-60-Yard/dp/B00004Z4BB/ref=sr_1_1?s=hi&ie=UTF8&qid=1371561766&sr=1-1&keywords=blue+painters+tape
12. ScotchWeld DP-190,
http://www.amazon.com/3M-Scotch-Weld-Adhesive-DP190-Translucent/dp/B0074N8N3W/ref=sr_1_1?s=hi&ie=UTF8&qid=1371558594&sr=1-1&keywords=scotchweld+dp190
(Optional) 3M Applicator Gun EPX Plus II and mixing tip, for ScotchWeld,
http://www.amazon.com/3M-Scotch-Weld-EPX-Plus-Applicator/dp/B001ANXYF4/ref=sr_1_fkmr0_3?s=hi&ie=UTF8&qid=1371558713&sr=1-3-fkmr0&keywords=scotchweld+dp190+applicator
13. Disposable Latex Rubber Glove, (for applying DP190 into mesh)*http://www.amazon.com/Stanley-Helpers-Disposable-Lightly-Powdered/dp/B000DILNJ6/ref=sr_1_7?s=hi&ie=UTF8&qid=1371558808&sr=1-7&keywords=disposable+rubber+gloves
14. Cloth or Rag,
http://www.amazon.com/Essentials-14-Inch-17-Inch-24-Pack-WT24/dp/B000ICRJ4A/ref=sr_1_1?s=hi&ie=UTF8&qid=1371565083&sr=1-1&keywords=cloth+rag+shop
15. Modeler or Xacto Knife,
http://www.amazon.com/Xacto-X3601-Precision-Knife-Safety/dp/B00009R8JZ/ref=sr_1_4?s=hi&ie=UTF8&qid=1371558896&sr=1-4&keywords=xacto+knife
16. Red Scotchbrite,http://www.mnpctech.com/3m_scotchbrite_pads_red.html
17. Filtered Respirator Mask,
http://www.amazon.com/3M-Low-Maintenance-Half-Mask-Respirator-Assembly/dp/B00004Z4EB/ref=sr_1_1?s=hi&ie=UTF8&qid=1371558931&sr=1-1&keywords=3m+filtered+respirator+mask
18. SEM Self Etching Primer, Black,
http://www.amazon.com/SEM-SEM39673-Etching-Primer--Aerosol/dp/B000PKZ3IY/ref=sr_1_cc_1?s=aps&ie=UTF8&qid=1371558960&sr=1-1-catcorr&keywords=sem+self+etching+black
19. Krylon "Rust Tough" Semi-Flat Black Enamel (or Plastikote "Engine" Enamel),*]http://www.amazon.com/Krylon-RTA9203-Semi-Flat-Preventive-Enamel/dp/B000RMTDAE/ref=sr_1_1?s=hi&ie=UTF8&qid=1371559001&sr=1-1&keywords=krylon+rust+tough+black+flat

Corsair Factory Front Bezel Plate.

Corsair gives you 3/16" gap around the plate from the factory for airflow. This modification will be huge improvement for cooling your system.

The front plate pulls off without any effort. It's removed for accessing and cleaning the Corsair 900D's three 120mm front cooling fans and filter.
You have option to remove the Four plastic mounting pegs, or leave them on throughout the entire modification process. It's your choice! The pegs are fastened on with Phillips head screws.

The best tape is 3M Scotch 233+ Green tape
3M Scotch Green 233+ masking tape is used by Automotive Paint Professionals. It's highly conformable to curved surfaces on both metal and plastic. It has good adhesion in a large range of weather conditions. It will peel off without leaving any sticky residue. Most Auto Body Supply Stores should be stocking this tape. It's also readily available online. 3M Scotch *233+ tape has a premium price compared to other tapes, but it performs the best*


The 900D front plate is made from Anodized Black aluminum. We're going to retain this factory finish.

Use Measuring Square or Ruler, to measure out 1" framed border around the Corsair's 900D plate

Put on your Safety Glasses, before using any Power Tools.
Using Rotary Tool with 1.5" Cutting Wheel, to make four incision cuts on each of the four sides. This step is necessary, before you can use the Jigsaw to remove the center.

Using Jigsaw with 18 TPI bi-metal cutting blade to remove the center of the plate you measured out.

The center section of the plate has been cut.

Using Hand File to fix and clean the jagged edges of the cut out. You'll want to remove the masking tape, so you can better view your progress with the file.
Modder's Mesh, Round,http://mnpctech.com/case-mods-gaming-pc-liquid-modding-custom-computer-mnpctech-overclock-cooling-fan-grills/modders-mesh-perforated-aluminum-steel-honeycomb-grill-intake-front-fan-slotted-diamond-round-hex/modders-mesh.html

I'm attaching Round Modder's Mesh to the backside of the front plate.

Measure out piece of Round Modder's Mesh to 15" LONG by 7.25" WIDE.

Use Tin Snip or Metal Cutting Shear to cut the Round Modder's Mesh

Attach the Round Modder's Mesh to backside of the front plate with Spring Loaded clamps. You can also use small C-clamps.

Apply Painter's Tape around the edge of the mesh on back on front side of the plate. This is to help prevent any ScotchWeld DP-190 epoxy from running off the Modders Mesh onto the plate.
[img=http://www.mnpctech.3dpixelnet.com/picture_library/CPUHood1lbwb.jpg[/img]
I'll be using ScotchWeld DP-190[font='Helvetica Neue', Helvetica, Arial, sans-serif]for*attaching the Round Modder's Mesh to backside of the plate.
You'll need to wear Latex gloves, when using the ScotchWeld DP-190.*You can manually push the two cylinders of Epoxy in DP-190 Cartridge onto a piece of cardboard. Then mix the two epoxies together with a long wood nail or pop-rivet.*Otherwise*3M sells a ScotchWeld Applicator Gun, for $70.00 with spiral mixing tip, for ScotchWeld

Wearing latex glove, use your finger to evenly smear the ScotchWeld DP-190 epoxy into the perforations of the Round Modder's Mesh

Use a cloth or rag, to wipe off any epoxy run-off from the sides of the plate

Wear filtered Respirator Mesh before applying any paint.
Apply paint in well ventilated area, preferably outdoors with temperature around 72F
I'm painting the backside of the mesh first, starting with coat of SEM brand self etching primer. Allow it to cure for one hour before applying Krylon "Rust Tough" "Semi-Flat" Black *paint. Allow "Rust Tough" to cure for 24 hours.

Mask off the front frame, and repeat same steps for painting the front of the plate.

After 24 hours, remove the tape.

Close up of the bezel plate.

Step back and admire your work!
You can use this technique to attach Modder's Mesh to create cooling vents in other panels.
Please share any questions or comments!

Almost makes me want to get a 800D case for my next tower....thanks for the info....

Sweet deff might chop my 900d

Glad you like it guys!
 
*the fans have filter screws over them

I think the vent holes on the 350D look a lot nicer than the typical mesh cutout. I tried the mesh cutout on the 350D grill and unfortunately it looks kinda silly because the fans are partially hidden by the case itself, so it doesn't have as nice a look as lets say the 750/900.
 
Luckily I've got another spare grill so I might have to do the vent holes. No CNC machine for me, so I guess ill have to pick a boring rainy day to hand drill lol.

you don't by chance have a template of that vent hole design for use do you?

No worries, I actually ended up starting to measure out the space and started pre-drilling everything with a smaller bit once I got everything marked. I did still stagger mine like the design shown instead of making all the holes line up for each line.  I'll probably finish it up this/next week and post up a picture.

We had to make larger fixture for drilling the ventilation holes in the 750D front plates, but turned out pretty good!, http://mnpctech.com/mnpctech-clear-case-pc-panels/corsair-750d-front-plate/corsair-750d-cnc-milled-vented-front-bezel-plate.html