Case Modding - Cutting Holes

[dragflameson]

When you guys cut a fan into the side or top of your case what do you use to do it? How is the best way to do it? Thanks.

-Drag

[Da_Flea]

i have only done it once....i used a drill to drill the hole then used wire cutters...used to cut aluminum siding....and cut out the holes......My buddies used to put filters over the holes....but i never have.....

[dragflameson]

it came out nice and round? not all crappy?

[rangeral]

The most common tool used for mods is a dremel tool, its about the most accurate and easy to use.

[badgern]

Use a tank cutter, you drill a hole about quarter inch diameter then use an allen key to pull the correct size tank cutter through the hole. No swarf and no rough edges.

[Bigjakkstaffa]

Because were poor we mark out the hole in pencil, then use a drill to drill holes in the centre and around the edges, we then use a rather **** jigsaw to cut through these drill holes leaving a rather jagged blowhole, we then sand like hellto make it smooth-ish... actually substitute We for my dad ;)

--jakk:t

[Giblet Plus!]

The easiest way is with a drill and a holesaw. Dremel tools or Jak's way work fine if you don't have a holesaw.

[COLN]

What not to use; a nibbler tool. After drilling a starting hole, it works but so slow and you still have to use a dremel or something else to smooth the edge.

[Bovon]

When you want it to look good, with no jagged edges ect...take it to a metal shop.

[dragflameson]

Thanks guys. I think I am going to buy a hole saw and dremel.

1. Do they make hole saws as big as 80mm fans?

2. Can I use a regular hand held electric drill to attach the hole saw to and use that to drill the hole? And then attach the dremel to it and use that to smoothen it? Or do I need a big powerful table drill to mount down the case side to and drill through like that?

Thanks again.

-Drag

[Scavenger7]

Yeah they make 80mm hole saws. and yes you can use a hand drill.. just make sure you clamp it down, or have someone there to help hold it steady..

:t

[bushmaster]

I use an 79.3mm porter cable hole saw and adapter that goes on my 1/2" porter cable drill. make sure you use the side handle because when cutting through metal if it binds it can cause serious damage to ones wrist. ie; use 2 hands.
But that cuts the holes clean and fast. Both attatchments for the drill cost about $30.
I also buy black abs plastic filter covers for 80mm fans that go on the outside of the case and secure with the screws that hold the fan in place and also have a removable bezel that holds a small filter.
My personal cases are antec 1080 amg's and need no further modding for cooling.

[dragflameson]

OK cool! Does anyone know where I can get em cheap online? Thanks.

-Drag

[Da_Flea]

Originally posted by Da_Flea
i have only done it once....i used a drill to drill the hole then used wire cutters...used to cut aluminum siding....and cut out the holes......My buddies used to put filters over the holes....but i never have.....

dremel to smooth edges.....

[bushmaster]

Does anyone know where I can get em cheap online?
Go outside into the sunlight and venture forth to your local hardware store or better yet Home depot, and you'll find everything you'll need and maybe even have some fun along the way. LOL.

[dragflameson]

bushmaster,
There are always better prices online. I guess my value of a dollar is much higher then yours, I have to work hard for my money.
Anyone know anyhwere online that sells these kinds of parts for cheap? Thanks.

-Drag

[rangeral]

Everybody works hard for there money, I was going to suggest the hole saw but investing in the dremel tool which is a power tool you'll find other uses for it as well unless you start making holes for your friends and charge them for it to recoup the monies spent.:)

[Giblet Plus!]

I just got a Black and Decker RTX for christmas, and boy, is it powerful! It has about 2 amps of power instead of 1.2 like the dremel. :eek:

It was $50 with a whole bunch of attachments and discs. :)

[dragflameson]

I already got a drill. Its just a normal drill used to drill holes in wood lol. :) Anyways I am just going to buy a hole saw bit and dremel bit to use on it I think.

Drag

[x51out]

I've tried it with a Dremel and it doesn't work as well for me as it apparently does for the other guys. What works best for me is a jigsaw with a small-toothed blade (for cutting metal). Mark the hole in pencil, drill a hole with a diameter equal to or larger than the jigsaw blade width on the edge of the 80mm circle (to get you started) and off you go. Be sure to keep the jigsaw rpm up as high as possible as metal requires a higher speed and smaller blade teeth than wood does. I've done three hole this way and it is a cinch. Easy as pie.:cool:

[Asonic]

If you are going to use a jigsaw then dont try to force it to cut to fast, its easier to keep close to the line and you wont burn out your jigsaw like i did:rolleyes:

[Bovon]

A sheet metal shop would probably charge you 5 bucks to punch a hole in that case for you..but if you must cut it yourself, work from the inside out...that way, if the drill, saw or dremel slips..the scarring will be on the inside...out of sight. Unless you can use a drill press and a holding device for the metal, that hole saw will move around a little bit, and the hole will not be as neat as you would like. Been there, done that.

[Giblet Plus!]

Originally posted by Bovon
that way, if the drill, saw or dremel slips..the scarring will be on the inside...out of sight.

Go slow, too. On my other case I made a side blowhole with a holesaw, and while it turned out nice and circular, there was a yellow ring around it where some of the paint had burned. :eek:

[Someone Stupid]

With a dremel (or similar tool, I'll just say Dremel for brevity) it's best to use previously ground disk to get the curve (which means you need to grind them on something if you aren't makeing a window with a straight cutaway). The smaller disk size allows you to get a MUCH better circle than a full sized round "bit." You WILL break bits, that is a given, especially when starting out, so wear protective eyewear (seriously - even with a jugsaw - **** does happen - it's worth the few seconds to don goggles to protect your eyes). Don't worry about broken bits, I've broken countless ones before I finally mastered it. It took me quite awhile before I wouldn't break bits (still break an occasional one), you just have to keep the revs up and go slowly and know exactly how far your "blade" is passing through the metal. Ideally you want it passing right at the end of the other side for it not to shatter. Keeping it at a right angle and even with how your cutting helps a helluva lot. When the disk gets small (halfway), let it cool down and save it for rounding corners and such and grab a new bit. Then when done get out a metal sander attachment (should be big and thick, and heavy), lightly go over the surface several times, on the last passes you may want to "round the edges," this is done by slightly angling the dremel, don't angle too much at once or you'll make a mess. To angle the outside smooth and flush correctly and without screwing up, expect three to five passes to get it clean and very smooth - I usually do it in three, but I make an additional pass just to make sure. But I've case modded a helluva lot - if you mess up, it's a learning experience - I've mauled the hell out of a couple cases, eventually used them for practice. :)

Just always keep the bit perpendicular to what your cutting and don't go deep. On curves smaller used disk are better, but if all you hvae it new disk, it's still doable, just a little harder to get a "perfect" cut. Good luck and don't be discouraged if it doesn't turn out right. If I had a camera I'd show you a case I jigsawed - it isn't pretty at all. We all have our learning experiences. :)

If you have to use a jigsaw, drill a hole for it to fit (in a part that will be cut out), rev it up all the way with a metal blade and keep it at full revs and go slow. Take advantage of the knob up top for turn, you should be turning it constantly, the second you aren't turning it, you are doing something wrong. You'll be turning it REALLY slow, but you'll be going really slow. It's possible to get clean cuts with a jigsaw, but it takes LOTS of practice, more than with a dremel like device. Then go over it with ametal file to smooth it out, it should have a coarse and a rough side. The coarse side should be used the first time around, maybe two if it's really messy, then go to the smooth side and clean it up.

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If your going for cheap, I'd go Bovon's route. I've done it before. Had two 120mm holes and one 80mm hole along with an 80mm metal tube cut to the length of my heatsinks fan for I think 20-25 dollars and tax. They charged about 5 to 7 a hole IIRC. That's probably your cheapest route if you don't want to go purchasing tools, and it will be professional. They even sanded mine smooth and rounded it (though I requested that). Cheaper than going out and buying tools you'll only use once.

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Gib: How you like the Black and Decker? I have one - my dad had it actually, didn't discover it until I came home and *****ed about how my dremel wasn't cutting well. He went into his shop and handed me a dusty box, opened it up and I found that baby. It has power to spare - broke a few less bits as well. If you mod a lot, like for friends, it pays for itself easily.

[dragflameson]

Someone Stupid,
Thanks for all the advice. Im going to go with the hole saw and then dremel, not the jig saw. I will post pic's eventually after I start my next build.

Drag

[Giblet Plus!]

Originally posted by Someone Stupid

Gib: How you like the Black and Decker? I have one - my dad had it actually, didn't discover it until I came home and *****ed about how my dremel wasn't cutting well. He went into his shop and handed me a dusty box, opened it up and I found that baby. It has power to spare - broke a few less bits as well. If you mod a lot, like for friends, it pays for itself easily.

I haven't had a chance to use it on my case yet, but it seems really powerful. I was goofing off with it, and I had a thin strip of balsa attached to it kinda like i fan. I turned it all the way up, and then made the spinning balsa touch my desk. The balsa took out a small chunk of the plastic on my desk! The balsa itself got burned on the edges, and almost started on fire.

Pretty scary. . .

[bushmaster]

There aren't always better prices online. Looking on-line does enable one to do price comparison side by side, thus finding the better bargain. Sometimes there are better prices to be had on-line in non brick and mortar stores or B & M online stores. But not always.
Plus factor in that sometimes you have to pay S + H. Not all the times, but sometimes.
Go into a loews and if you have an idea of what the prices are for the item your looking for you might just be suprised.

I have a dremel tool set that I have seen on-line for $78 and that was the best price I could find and was debating buying it on-line untill I purchased it at a Loews near me for $57.97 + 7 1/4% tax.
I saved s + h and picked up my hole saw at the same time.

Loews stores are nothing but huge inventory warehouses, with inventory clerks and cashiers as opposed to inventory clerks and shipping clerks that an on-line store would need. Plus alot of on-line stores are nothing more than middlemen who take your order, make their percentage, and have their supplier ship to you.

P.S. guys. When you cut or drill metal use the low speed so your cutting tool doesnt get hot and burn. Not only will it mess up the finish on your case but the heat kills the bit's or saw's teeth making it dull and pretty much useless. slow and easy makes for a clean cut and no accidents.

[cparker]

Bush is right about Lowes. I have bought most of my shop tools from them. My Plainer, Jointer, Table Saw, and Router will all cheaper and Lowes then any on-line store (if you included shipping). On-line is a great place to get an idea of what you should pay, but for some items it pays to search locally.

[dragflameson]

Yeah, I think I am going to go and take a look at what kinds of dremel kits they got. My buddy says he knows of one thats not too expensive and said it comes with about 50 different heads. And then Ill just buy the hole saw bit for my drill.

Drag