USB Bracket Completed
This is the mounting bracket for the USB ports that will sit in the cable bay of the chassis, up near the top:
Here's a look at it from the bottom . . .
This part was once a flat piece of aluminum that I bent into an aluminum angle with the lightweight metal bender. I could just as easily have used store-bought aluminum angle, but I didn't have any handy. On each end, I cut one side of the angle off, then used the vise to bend the remaining side around for a mounting flange.
I drilled the eight holes for the mounting screws, and then drilled four 1/4-inch (~6mm) holes for the ports. I rough-opened the port holes to 1/4 x 9/16 inch (~6 x 14mm) with a Dremel-type cutting wheel on a power drill, and used a small triangular hand file for the finish work.
Here's a closer look at the end detail:
This isn't a part that anyone is going to see, so I wasn't all that precise in filing the slots for the USB ports. I cleaned all the edges up with the small file. When I was done, I drilled mounting holes in the end, and punched matching holes in the chassis side panels.
Once again, the punch was far cleaner than the drill. Instead of completely disassembling the chassis to keep from getting grill chips in the electronics, I just took out the two screws holding the rear mainboard mounts to make space for the punch. It left four little discs in my hand, and there was no cleanup needed on the side panels.
Next, I'll fasten the bracket into the chassis and get the PC assembled and ready for installation.