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Cutting Cleanly
The first obivous trick to a clean cut is having a good tool. Good drill bits, and sharp blades are safer and easier to use than dull ones. They also leave a better edge.
After you have made the desired cut, you can got back with a dremel tool to clean up the edge. By doing this, you will prevent loosing fingers when you feel your beautiful handy work.
Don't be afraid to cover-up. I saw on a few blow-hole sites, where they used automotive door trim to cover the edge of a hole. This gave a true professional look, and really helps in saving fingers later down the road.
Painting your case will hide many mistakes as well. Just be sure to properly prep your case with sanding and the use primer. Remember, that painting will not always hide a mistake. There will be cases where the paint will amplify the mistake.
Placing felt on the bottom of jigsaw works well when you are forced to cut on the painted side of a panel. Just be sure to keep any metal shavings out of the felt so that later you will not defeat the purpose of the felt.
Check out The Catolog Page for picture of the jigsaw and drill we use.
Planning
Now that you understand the basics of case modding, you must know that that the key in completing the bost looking mod is planning. Without planning you are more open to mistakes, and injury. I will not deny the fact that I have made mistakes that have actually turned out to make my projects better.
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