I just got my first XPC, a SN41G2 V3.
I cut my grille out before I even put a processor in it thanks to you guys on this forum
(esp hydran, thanks for your guides man).
I notice you didn't file the edges, I highly recommend it, I turned the XPC upside down on a piece of cardboard and just filed away with a big metal file, it didn't take that much time and makes a world of difference.
I used the fan gaurd already inside to put on the outside of mine, nothing was anywhere near it anyway (certaintly not my fingers for sure
I tried to mount the fan on the outside of the cage, but my DVD burner was too long, darn.
I like the USB ports though