Allright, a bit of a respit from the front as I debate on how to do the fan intakes. In the past I've used fan ducts as sold here by mnpctech.com:
Computer Case Mod Cooling Fan Duct
and although they work great the one thing I don't like about them is that their diameter is a bit smaller than the full span of the fan. You don't really notice once the fan is up and running but I'd prefer to have a full 120mm blow hole if I'm installing a 120mm fan.
So, onto the feet while I sort that out. I'm going use acrylic blue and white to match the paint job of the case. First step is to hole saw the feet out:
Once cut out you can see they are pretty rough:
I use a little acrylic adhesive to glue them together in sets of three: Blue-White-Blue. They are still pretty rough, you can see the tooth marks of the hole saw teeth.
Next I use the belt sander to get rid of the worst of the markings but the belt sander doesn't do well on round surfaces so I pass a bolt through them to attach them to the drill press:
This way I can sand them all at one time and make sure all the feet are exactly the same size. You can see here the progression as I more from 80 grit to finer and finer sandpapers:
Once all sanded I enlarge the original hole on one end to compensate for the bolt head that needs to be buried into the foot.
Here you have the almost finished feet, you can see the bolt through the one and the bolt head on the other that you would see inside the case on the floor.
The final step is to put them back on the drill press and blow torch them for a final polish. Here you see the difference between the 1500 grit and the blow torch finish.
It's hard to see in RL but you can see a few minor imperfections on the polished foot, I'll give it another round of sanding and re-buffing to get rid of those. But that's enough for today.