Instructables
Picture of Screaming Skull Xbox 360 Case
I wanted a way to mod my Xbox 360 case to make it one of a kind. This is something i have never seen anyone else do. Having a screaming skull inside the xbox trying to push itself out through the side. The skull is actually for a PS3 case cover.
 
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Step 1: Materials

Picture of Materials
bondo-repair.jpg
bondo.jpg
You need to gather all of your materials you will need.

1. Screaming Skull found here for $11
2. Bondo Body Filler
3. Bondo Glazing & Spot putty
4. Plastic Epoxy
5. Sandpaper 60/80, 220, 400, 600, 800, 2000
6. Tack cloth
7. Primer the kind you can sand
8. Spray paint of you choice. recommend Kylon Fusion because it is made for plastic.

Step 2: Mounting the Skull

Using the plastic 2 part epoxy glue the skull to the case. Because the skull doesn't fit flush you will have to hold it down until the glue dries. Mine took 12 minutes but it was worth it. When adding the epoxy you don't need to have it all the way around the skull. Only in key point to keep it held down until you can bondo it. I sanded the case and the skull to help the epoxy and bondo grip better.

After the epoxy has dried mix your bondo. Just follow the directions on the product. You should have a nice light pink color when it is mixed properly. Make sure you tape off the hold on the top and bottom of the case. It will be a pain to get the bondo out of the holes. After you have applied the bondo you can remove the tape. Make sure to remove it before it dries though.

Let the bondo dry for 30-45 minutes.

You can learn more about bondo here.

Step 3: Sanding and more Sanding

This is the most time consuming part of the project.

Start with the 80 grit sandpaper and smooth out the bondo. Once you have it blended nicely at the edges and it shaped the way you want it you need to apply the bondo glazing putty. Let the glazing dry for 30 to 45 minutes.

After the glazing its dry use the 220 grit sand it off. The only red left from the glazing should be in the imperfections in the bondo.

Apply another coat of glazing and sand it with the 400 grit sandpaper. Then apply a 3rd coat and sand with the 600 grit sand paper.

Step 4: Primer

Ok, you are on the home stretch.

Tape off the front side of the case so you don't get paint on it.

Once you have the surface completely smooth you are going to apply 3 coats of primer. Allow them to dry completely. I'd wait at least 2 hours to be sure. Using the 800 grit you need to wet sand the primer. Sand it down so that there is almost no primer left.

Then apply 2 more coats of primer. Wet sand again with the 2000 grit sand paper. You can find this at an automotive parts store or walmart.

Step 5: Painting

Last step is painting.

Now that you have it completely smooth its time to paint. Even though you have the surface super smooth the paint will still stick. If you are using Krylon Fusion paint because it is meant for plastic, which is even smoother than you have your surface now.

Paint as desired. I used 3 coats of flat black to minimize glare and show depth better.

If you are looking for a mirror finish you can read this instructable.
Uratz5 years ago
Does this risk the XBOX heating up more since there's a pocket of air inside and can't escape?
Zachterling (author)  Uratz5 years ago
No absolutely not. In actuality it would help with the heating. Because it puts more "open air" between the heatsink and the case.
unless you actually cut a hole behind the skull it will act as insulation, which may or may not raise internal temp, too tired to do math atm.
He did do that, remember?
sneaky edit imo :P
What type of primer did you use for doing this? It looks awsome by the way. I am going to try to mod my console too. Do you think this same mod would work with a walmart mask or something like that?
You don't need primer. I spraypainted my girlfriend's xbox, and it came out fine without it. And yes, it probably would, but I'd buy a few spare cases, to allow for screw ups.
AF505 years ago
shibby
WHAT?
megapun134 years ago
I added another fan where the skull's mouth is, and put some very tight scope cover(its like bug netting, except it comes in multiple colors, I chose black, and its hard to see through unless its used as its made for[scopes]). Then I added a red LED in the fan. So the skull is like, breathing out. Its sick, dude.
badboypl34 years ago
Awesome tutorial man!
nickodemus4 years ago
That is pretty epic!!
jacumja5 years ago
Anybody know what its called when map's, posters etc. have that 3 dimensional look? I hope I'm asking clearly. I always loved the maps that were like this.
A 3D map is a Topographical Map. Look up topography. Interesting stuff, somewhat confusing to make.
Some Dork5 years ago
Holy hell this is very cool!  Sweet find on the skull cover and great work integrating it onto the 360 case. 
pwn1god5 years ago
Im doing this right now, well i ordered the skull, ill post results when im done
otoupalik5 years ago
That's SICK! I love it.
bruno855 years ago
cool
Izokay5 years ago
This is the coolest Xbox mod on Instructables! Faved.
gover575 years ago
should've done han solo's face, lol. sorry - couldn't help - it looks too much like a rotting face stuck in carbonite...
snorkledorf5 years ago
NICE JOB !!!
lemonie5 years ago
The final finish is very good - a lot of sanding? L
Zachterling (author)  lemonie5 years ago
yes, many many hours spent sanding. i admit i probably should have done more sanding.
It looks like you've done enough, but I know what these jobs can be like - the final result is worth it (or should be)

L
Dandeman3215 years ago
Looks great! You should add some LED lighting coming from the vents to add to the effect that something is trying to come out of your xbox!