Use a Dremel (tool) to Modify a Dremel (case)

Time for another great Instructables Build Night at Omaha Maker Group! This month, the fine folks at Dremel supplied us with a whole slew of GREAT products! In our makerspace, however, we rarely keep tools in their original cases, opting instead for hooks and/or shelves that make the tools easy to get to, and easy to put back into place. But we didn't want to just throw away the nice cases that the rotary and multi-max tools came with, so we started bouncing around ideas on how to repurpose them. Brandon and I thought it would make a perfect Build Night Instructable to use the Dremel tools to modify the very cases they came in!

For the purposes of this Instructable, Brandon modified a rotary-tool case to make a nice carrying case for his RC radio and some quadcopter parts and accessories.

What you'll need:

- A Dremel Case

- Dremel rotary and Multi Max tools, with a variety of bits

- Hot Glue Gun and sticks

- Foam padding (available from your local fabric/craft store)

- Safety gear

- A Sharpie

Step 1: Size Things Up!

The first thing we needed to do was make sure that the radio and other parts would fit in the case. This also gave us an idea of how much of the case interior would need to be modified (all of it).

Step 2: Start Cutting!

We installed the small saw blade into the Multi Max and started to cut through the layer of plastic that secured the inner part of the case to the outer part of the case. The Multi Max easily cut through the plastic freehand, with little guidance.

Step 3: Don't Forget to Be Safe!

Don't think for a minute that we ignored safety. Brandon has safety glasses on, has the work piece on a stable surface (with a non-slip pad underneath), and has positioned himself so he can guide the workpiece without getting close to the cutting point. We also made sure the workbench was well let and the power cable was out of the way.

Step 4: Bring on the Rotary Tool!

For the corners, we found that it was easier to use the rotary cutting bit of the rotary tool rather than trying to move the Multi Max into the tight corners. Once all the corners and sides were cut free, you could start to see the inner layer separating from the outer layer. But there was still the matter of the weld points between the layers.

Step 5: Saw! Chisel! Scrape!

Continuing back with the Multi Max, we used the saw and scraper blades to cut through the round weld discs between the layers. Then Brandon switched back to the scraper blade and cleared away the bigger chunks of plastic.

Step 6: Sand It Smooth

Now it's time to finish up with the tools. Brandon switched the Multi Max to the triangular sanding pad, and used the included sandpaper to clean up all the rough edges and surfaces.

Step 7: Make It a Padded Room

It's time to fit it all in the case and protect the contents. After laying out where the radio would go, Brandon marked the clearances need for the controls and sticks. He then cut the padding to size and checked the fit. Next up: the hot glue! What makerspace couldn't function without the hot glue gun?!?!?!

Step 8: All Finished!

And here's our finished project! Not only did we save the case from the landfill, we managed to create a custom case for the RC control that is exactly what we wanted!