Best tool to cut holes in a case ...

[Fun Guy]

OK, not "chop up" a case, but I want to (1) put a blowhole in one case, and (2) knock out the perforated area in the back of another case so the fan I mount will have free airflow outward This is the case - see the back of it where the 80mm fan can be mounted, this is what I want to knock out

I have no tools now except a drill. I have heard of this thing called a 'nibbler' but don't know if it is any good, or even where to get it. I've used a Dremel before but not on metal this thick, so I don't know if it would work properly. Anyone have experience with either one of those tools? How about anything else?

 

[Vpham97]

I though you wanted to destroy your case. I was going to suggest to wait for a bad day, than you can use your shotgun.

 

[robinhung]

Have you heard of Rotozip? It's on TV and you can find it in Homedepot. Or go to www.rotozip.com.
I think it's the best tool to mod anything.

 

[Ronstang]

If you have a drill then the best tool will be a bimetal holesaw. You can get them at Lowe's or Home Depot. Depending on size they range in price from a few bucks to about $20. You need to spin them slow to prevent heat build up, but hey cut quick and clean with a little practice

 

[Fun Guy]

Do they make an 80mm holesaw? If so, wouldn't it be kind of dangerous to use one?

 

[pdo]

You can get a (nib) I think that's what it's called for like $10 bucks at Home Depot and it'll cut through it in 10 seconds.

 

[mechBgon]

You would certainly want to take precautions if you're working on a sheet of metal... don't want it free to spin on you. I would also point out that the larger the holesaw, the more expensive. You could consider a smaller 60mm high-output fan if you don't mind it being noisier. The 27cfm Y.S. Tech is a very powerful dual-ball-bearing fan and the hole saw would cost a lot less for a fan that size. You might even find one around the house that's sized for doorknob installation that would work.

 

[VladTrishkin]

Nothing (well, almost) gets better then a 78MM hole-saw and a high-power drill

 

[Max Power]

Ditto on the holesaw idea.

Check the link in my sig to my case and pix of the mods I did--all holes cut with holesaws.

 

[DainBrammage]

If you already have a dremel use it. I,ve cut open 81mm Yugo mortars with them, they will work fine on the cheesey sheetmetal of any case. Use the larger cutoff wheels that are fiberglass reinforced. If your a shakey jake then go to Lowes (any large hardware store will do) and get the spiral cutting saw kit for your dremel turn your dremel into a little Rotozip only for about $14.00 and it comes with three bits and the attachment to act as a platform.

 

[Mookie]

I used a jigsaw to cut the openings for two 80mm fans in the back of my case. Draw your circle and work carefully and you can get a pretty clean opening. I tried a dremel and didn't like it, but I wasn't using a spiral kit mentioned by DainBrammage, that just might work.
The hole saw is probably best, but I was turned off by the cost. When you start looking at the $ for ones large enough to cut 80mm and 120 mm....ouch!! RotoZip works great for cutting plastic like the front cover of the computer if you want to add a larger intake. You can cut the metal case with a jigsaw or even hacksaw, because you really don't see the metal if you use a grill between the plastic front and metal case.

Just my 2 penny's

Mookie

 

[Mookie]

I came accross this link further down in another topic. It shows how they used a jig saw to cut a blow hole in top of the case. I don't disagree that a hole saw will do a cleaner job, but unless you got more uses for a 120mm hole saw, I'd go with the jig saw. Use a nice chrome grill and the blow hole will look a lot cleaner.
Blowhole

Mookie

 

[pen^2]

whatever you use, just dont go with a hand nibbler. i was fooled by someone else's remark on this forums and found it out the hard way that it wasnt the right tool to use. it gets job done, but you end up with rough twisted edges and blisters on your hands

 

[tweakr]

Well, speaking from painful experience, a 116mm Holesaw is a serious pain to control - especially when you're using a drill with two settings - off and bloomin' fast.... However, a 76mm holesaw is a far more manageable, and one holesaw has lasted me through about 4 case mod jobs before even starting to look blunted - note I seem to have managed to buy the strongest mini-tower in the UK, the steel's thicker than my mates SC-760A... If you own a variable-speed drill it should be a lot easier, simply use the lowest setting, but go very slowly if using a high-torque drill...

cheers
tweakr

 

[DanceCraft]

While the hole saw is the best its also the most expensive. I read that some people were using a roto zip, well I would recommend getting a dremel tool instead. The roto zip is more of a wood working tool/angle grinder. The dremel tool is an all around everthing tool. Just cut the hole a little undersized and get a grinding weel and smooth it out. Even with a jigsaw you will still need to cleen up the hole. Pretty much the dremel tool is the best tool you will ever buy, cause it does everything you can imagine. Infact I'm even using it to mill out a water block in copper. It may not be the best tool for cutting out a hole in your case, but it will do just about everything.

DanceCraft

 

[Mule]

I've using nothing but jigsaws to mod my cases, no extra cash to spend!!! muhahahaha

 

[NutBucket]

MotoTool. Besides, it has 1,000,000 other uses!

 

[Redman7]

I borrowed a knockout from work from the electricians.
A knockout is a hydraulic tool for cutting out holes in electrical cabinets for conduit.
Used a 4" and 2 1/2" (conduit sizes) for 120mm and 80mm fans.
It worked awesome. Very quick and very clean.
If you can borrow one, you'll be glad you did.