Custom fan grills help

[goodgod]

(For those who didn't see my mod, the link is in my sig.)

So I'm thinking of doing custom Pure Pwnage fan grills, 4 of them, to complete the mod's PP style. Here's a little paint and photoshop art to show you what's my idea.

As you can see, details are little and must be precise (this is Jeremy silouhette BTW, the star of the internet show Pure Pwnage). I don't know on what material to work (metal, acrylic, etc...), and I still don't know if the fan grill will be made in two parts, then glued (one part the round and rounded square, the other the silouhette) or if this will be cut all together in a large piece of material.

Anyone got an idea on how to do these grills (at low cost if possible :cool: ) ?

[goodgod]

LOL! I just realized that I forgot to link the image, so here's the idea I was talking about...

http://img206.imageshack.us/img206/4539/ppgrill7rh.jpg

[Captain Slug]

It would be easiest to make it in two pieces out of acrylic or polycarbonate sheet then adhere them together with solvent.

[goodgod]

ok, I could buy black acrylic, do the rounded squares with a cutter, pierce the hole with a hole saw, then hand carv the silouhette with my artist knife (the one i'm using to carv little letters on a black plastic bezel, works good)

I think it would be good to carv the silouhette in a thinner acrylic, it'll be easier.

Then I can use epoxy glue or something else to glue them together.

I wanted to reduce the airflow of these fans, because they are quite noisy, and because if I reduce their power, the LEDs on them won't light up, but i'll see if it sounds better with the 80mm Anti-Vibration Fan Gasket that i bought this week (still waiting for a shipping from adpmods.com).

Maybe i can put a sheet of pierced aluminium on the fan to reduce the airflow or w/e, i'll see that later.

[Adragontattoo]

Use epoxy to glue clear plastics together as superglue tends to haze the plexi.

[Captain Slug]

The most effective solvent you can use with acrylic, polycarbonate, polyester, and ABS is IPS Weld-on #3. You can order it through McMaster (http://www.mcmaster.com) (search for part# 7528A13) or most local plastic shops.

[Chunkylover763]

I wanted to reduce the airflow of these fans, because they are quite noisy, and because if I reduce their power, the LEDs on them won't light up, but i'll see if it sounds better with the 80mm Anti-Vibration Fan Gasket that i bought this week (still waiting for a shipping from adpmods.com).

Maybe i can put a sheet of pierced aluminium on the fan to reduce the airflow or w/e, i'll see that later.
Putting a fan grill up to reduce the airflow is more likely to produce MORE noise, fans are always quiettest when unobstructed.