Case Mod How-To for the Alix Single Board Computer

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You’ll need a number of tools for this case mod:

First and foremost, you’ll need a Dremel rotary tool to do the “heavy lifting”. I chose to use the Dremel 400 Series XPR rotary tool.
Next, you’ll need a cutting wheel to cut through the soft aluminum of the case. I used the Dremel EZ456 EZ Lock Cut-off Wheel teamed with the Dremel EZ402 EZ Lock Mandrel. I used the wheel to cut the top and bottom of the slot.
You’ll also need a Dremel 150 1/8″ Drill Bit to cut the left and right sides of the slot.
Lastly, you’ll need precision files for fine-tuning the cut.

If you’ve got a little more cash, the following optional Dremel accessories will make your life a lot easier:

Dremel Multi-Vise. The vise will help you hold the Alix case steady while you cut it.
Dremel Flex Shaft. This is probably the most useful Dremel accessory. It gives you pen-like control of the Dremel rotary tool.
Dremel Flex Shaft Tool Holder. This is handy for hanging your Dremel rotary tool, which is recommended when you use the Flex Shaft.

Here are some photos of the tools I used.