So as promised, update with pictures!
So I re-did the drawing for the front panel, making sure there was enough space between the steel and the actual panel to install my intake fan.
All ready and set to use the jigsaw...god I hate using the jigsaw...

Turns out the distance between the cutting blade and the guides is an inch and a quarter, the exact same distance between my lines, so that was easy to set up!
Soooo....I didn't go that straight first and got a little bit of the bench too....ok a lot
Never thought it would work, but it was much easier to cut the corners with these then using a dremel!!! And it made the edge non-sharp!
Sooo after half an hour of sweating, bending, cursing, bleeding, cursing some more, hammering, got this open box design, SWEET!
Drilled the holes to screw it in the front panel.
Gotta love measuring 5 times and cutting once, it was a perfect fit, yippy!
So I'll be tackling cutting the drive bay, fan hole, power button and switches hole tomorrow or this weekend depending on my work schedule.
Also, here's a little shot of my paint tests, the only surface that's actually sanded and all is the weird shape in the middle. This is after 6 layers of primer and wet sanding with 400 grit in between, can't see it, but it's a lot nice and smoother then the surrounding paint, looking very sharp! Gonna start painting the black on it if temperature allows it also in the coming days!

I just realized, this is no the final shot, this is after 4 layers, I'll take another picture tomorrow.
Cheers,
Thx guys!