Like any other case mod you have to take things apart and this one was no different, but with everything being so small it was rather easy to do. But this also creates the challenge of where do you put things into a case that is only 6 inches across and most of the inside is taking up with hardware.
Here we see the main parts out of the case. I removed the hard drive, the memory, WiFi antennas, and the blue LED ring.
My first stumbling block was that the OI520 axis is kind of at a 45 degree angle through the case. This really made me think about the placement of the laser gun. Do I make it where it should be, just above the trench or do I make it at the position that your eye would catch it more. I went with just about the trench because If I did not I knew I would get a bunch of crap about it. The blue tape with the line through is a leveling point that I would use to help guide me lay out the ray dish and the painting if the surface detail.
So what is the easiest way to make the hole, well with a hole saw in a drill. Oh yeah then all you have to do it flip it over and you have the con-cave section of the laser cannon… uh not quite. Using the hole saw means you have to remove material with the cut and that leaves a gap and the piece you just cut out will not fit.
So I cut a circle out of some styrene plastic sheet and found something that I could use as a mold to get the right curve to the piece. Using a heat gun I got the piece hot, press down on it with a glove and molded it.