Front Cross Bar Removal: After debating on whether to leave the cross brace or take it out; I decided it needed to be removed. This brace is here for those of you who may want to use an optical drive. I won't be using one so it's got to go. It's an aesthetic choice and won't make any difference performance wise. I used a hand or hobby saw to cut the pieces out and now I need to file and sand the edges. The lexan fan surround will cover up part of it. Painters tape was laid down so that the saw didn't rub against the plastic causing more work. The area remained rigid, even after removing the cross brace.
Update: Front Lexan Fan Surround I've finished the updated template for the front fan surround. I always mount my templates using painter's tape. Doing so creates a contrast for the cut line and it also helps to stop the acrylic from melting. Once that was squared away it was time to cut it out on my scroll saw. Having a scroll saw is an important tool for any Modder to have. They are fairly affordable and can be used on a lot of different materials. The one I own was bought used and it's almost 10 yrs old but, it still works great. When I first test fitted the freshly cut pieces I quickly realized that I needed to notch out a couple spots to give it a perfect fit. The majority of this piece of lexan will be covered by either stainless steel or sheet metal. Spots will be cut out allowing the lexan to show through when its edge lit.
Pro Modder Tip: Cutting Acrylics In order to cut acrylic with a scroll saw or jig saw you need to make sure the acrylic doesn't heat up too much or it'll re-fuse itself back together. There are several methods I use to help counteract this. Painters tape helps a lot. I always place it over the areas I'm planning to cut and then draw my cut line over top. Using a blade with a lot of teeth also helps. One of the main factors is speed. The faster your blade moves; the more heat is created causing the material to melt. Using a combination of these methods will help assure that your acrylics will be cut cleanly.
Mocking Up Hardware: EVGA Even though it's a bit early to put hardware in, I still like to as soon as possible so that I can make sure everything is where I think it will be. I also like to do it as it inspires me to design the mods that will be done to the hardware. After looking at the cable connections I realized that I'll need to cut a passthrough in the PSU shroud in order to run the 8-pin power cable to the motherboard. This won't be difficult to do once I determine the location that will look best. After checking the rest of the cables I feel that I'm in good shape. Be Quiet did a good job on placing the majority of the passthrough needed to cleanly install a system.