PSU case PCB mounts

I played around with a dead PSU case.  It turns out that I don't need a press and dies to make the screw mounts they have.

First I measured and drilled the mounting holes I need.  I marked and used my Dremel cutting wheel for the vertical cuts on the sides of the mounting holes.

I made a jig out of a piece of scrap steel angle bracket.  I drilled out three 9/64" dia. holes for the 6-32 screws.

The holes on both ends are for mounting standoffs.  

This jig is mounted over the drilled hole in the PSU panel.  The screw in the middle is used for pulling and deforming the panel.  The standoff on both side pushes against the panel as it deforms.

Side view showing the bent area.

view from the back showing the bent

I didn't leave enough metal on the two sides of the drilled hole, so the metal cracked.  The hole got elongated as the metal stretched.

The large nut probably caused excessive bending on the sides, so I use screw head on the panel side for the remainder of the mounts.

The upper right corner was part of the original PSU mounts.  I did a slightly better job by the time I did the last mount in the upper left hand corner.

Now I can mount my 3"x5" open frame PSU module in the old PSU case.