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Fans how to cut holes in my case

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DanFraser

Member
Joined
Mar 6, 2002
Location
Derby UK
Well, I am about to do my own case mod, which does include a few fans... I have planned out my procedure for doing the cutting... first of all, draw the screw holes in pencil, then drill these... make sure you get it where you want! (measure it out so it is squared with the edges of the case)... then attach the fan (loosely) and draw out the size of the circle to cut using the edge of the fan case (the ciclre in which the fan rotates), then remove fan... cut circle... smooth off, then line with something to give a smooth clean edge (like what you would use for the window, if you add one, but smaller), then attach the fan and grill, and there you are! Preparation is the key! As I was told so many times by my ex-army Painting and Decorating trainer...
 

Hotsauce

Member
Joined
Feb 28, 2002
Location
Columbus, IN.
I haven't gotten aroung to cutting my holes yet, but I did read somewhere that it is a very good idea to tape the area with about 5 or 6 layers of duct tape before you do any drilling or cutting.

I was under the impression that this is to help prevent the paint on your case from chipping off. That is assuming that you are not planning to repaint your case.

Let me know how it comes out, hope this helps.
 

stool

Senior Member
Joined
Dec 20, 2000
Location
Albany, NY
If you are using a 120mm fan, use a CD as a template. Works perfectly. As Hotsauce mentioned, tape around the template if you are using a jigsaw. With a Dremel or nibbler you don't have to be as fussy. If you have any available and are using a jigsaw, put a thin peice of plywood behind your cut, this helps reduce vibration and errors while cutting. If you can afford it, use a metal-cutting holesaw, as the cut is extremely neat.
 

ed2lv

Registered
Joined
Feb 10, 2002
Location
Las Vegas NV
I used a drill with googles. Start with wide masking tape to mark. Do the big holes first then match with actual fan. The small holes (mounting) are the hardest because they almost have to be perfectly aligned. If you have a grill and want a big "blowhole" use metal snippers.
Of couse be sure not to leave any metal scraps or the mobo will shorten out.
ec.
 

klosters64a

Senior Member
Joined
Dec 17, 2000
Location
Seattle, Wa
Measure twice, cut once. Use the interior side of the case/panel to draw lines on and cut from the inside side, too. Use ink for drawing lines and circles. The "lead" in pencils is electrically conductive.

All you have to have is: 2.5 inch or bigger clamps(and 4 ~1" x 1" thin wooden blocks to prevent the clamps from denting the sheet metal), a small common(flat blade)screwdriver["chisel"], a sharp screw or nail that's 1.5 inches long["center punch"], a hard-heeled shoe["hammer"], a 3/8" power drill(NOT cordless), 1/8" drill bits, a flat ~2' x 2' piece of wood to clamp the case cover to-- so that it's safe for the drill bit to drill into it for ~1/4 of an inch, and a full round needle file(for removing burrs from the fan's screw holes--plus for making the screw holes bigger. 1/8" is too small). And a half-round file for metal. A half-round needle file will do, but a normal size half-round makes it much easier.

Drilling ~150 1/8th inch holes around a circle for a 120mm fan is a royal PITA. If you gotta use basic tools for good cooling, you will mount those fans the hard way. But you'll HAVE those fans!
 

Hotsauce

Member
Joined
Feb 28, 2002
Location
Columbus, IN.
Hole Saw...all i have to say..

Wow! that row of fans looks great! You convinced me, I was debating on what to use when I cut my holes. I was under the impression that hole saws didn't come that big. Looks like I'll be making a trip to the local hardware store.
 

arden

Member
Joined
Feb 17, 2002
Location
Pa.
If you know anyone in tool and die see if they will cut them on a cnc mill does a perfect job