Let the screwing begin:
Now that i've gotten the window cut out done and the lexan cut to the desired size, it's time to combine the two.  To do so, i used a 9.6 volt cordless drill with a #23 (.1540) drill bit designed for metal drilling. This will be sufficient to drill through the case and the lexan.  The screws that i used are sized at 8/32 with a length of 1/2".  The appropriate sized washers and bolts were used also. 

To make sure that the holes on both the case and lexan will match up, i simply tapped the lexan to the case at where i want it to be attached.  Dont be stingy on the tapping, you dont want the lexan to move while you are drilling or anything like that.  Once tapped down, the drilling can begin.  My holes (hehe) are all roughly about 3.5-4 inches apart, depending on the sides...it's different each side. But it is a must to have screws at each and every corner.  The picture shows the lexan attached to the case by the screws.

You might also notice that i've also have the blow hole outlined on the lexan. This is the next and possibly the last step to this project (yea!).  The fan that i will be using as a blow hole will be a 92mm Panaflo made by Panasonic (i bet you didnt know they make fans). There are a few ways that you can cut this blow hole. The best way is with a hole saw. With the hole saw you get perfect circles everytime at a fraction of the time.  I was hoping to be able to use one of these but unfortunately could not get my grubby hands on one.  Another way is with a dremel, good tool and will get the job done. I didnt have a dremel either, so there that goes. So i pulled out the ol' jig saw, drilled a pilot hole and cut away. Not the best or the roundest circle known to man, but was the best i can do in 3 minutes. Hey, whatever works. Again, sand the inside edges just a bit to get rid of any rough cutting.

For attaching the fan, i used the same size screws as i did for the case but a different length of 1.5".

This is it.  All you have to do now is put the puzzle peices together. Screw the lexan in place, tear the protective covering off the window and attach the fan and assesories.  Sit back and enjoy your new custom case...preferably with some sort of alcoholic beverage and a cigarette, or cigar if you're rich.

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Window and Blow Hole: Part 3