by jpark - March 25th, 2010, 9:54 am
Thanks!
First, I'd also remove all of the 3M tape from the inside and get a new roll of 3M double-sided black automotive tape.
I'd use a Dremel tool with a fine cutter after you mask the area, and carefully cut it about 1/16" (2mm) below your desired cut line. Then flat-sand the surface to the line with 120-grit sandpaper, and finish it smooth with 600 or 800-grit wet/dry sandpaper.
Wax the entire exterior and the cut surfaces. Since the chrome finish is bonded to the ABS plastic, you shouldn't have any problems with chipping as long as the edge is perfectly smooth. Then clean the inside of the cover with isopropyl alcohol and apply the new 3M tape right to the bottom edge and all along every other edge. This way, you won't have edges exposed with gaps, and the finished edges will look better.
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