Case modding help

[keljaden]

I have a Cooler Master 5 CAT-T05-WW
http://www.newegg.com/Product/...x?Item=N82E16811119077

It has a Plexiglas side panel and I would like to use a hole saw to make a 120mm hole in the side to mount another 120mm fan.

Will the plexiglass shatter or crack? How should I go about this, I also have a dremel tool available too.

And my temps are CPU 42 C Idle and Internal air temp 32 C
My 8800GT from Asus was a dud so I am borrowing my friends 8500 until my new 8800GT arrives (i am buying a pci exhaust fan to help with the heat that the 8800GT will emit)

I am also replacing the rear fan with a 120mm that has 110 CMF which is what the side intake will have as well.

I need the side intake fan because the front 80mm fan fails to generate enough CMF and airflow to cool everything to what I want.

I am aiming to decrease my temps by around 5C with this.

I notice people keep viewing this topic but not posting, doesn't anyone have any advice or experience with this?

 

[WoodButcher]

Remove the plexi from the case if possible, mask both sides, use double sided tape to adhere the sheet to a scrap of wood bigger than the your panel. You don't need lots of DS tape, just a couple of pieces to keep the sheet from sliding around and scratching itself, don't use clamps, the risk of cracking is great, the tape and your hand pressure will do fine. Have at it w/ the holesaw. Start slow, not alot of downward force is needed. A little fine sandpaper 220 is good, and then flash the edge w/ a torch and your done. practice the torch bit on your scrap first, works great if you're careful.

 

[keljaden]

Thanks so much for the help, Do you suggest just a piece of plywood? I also was going to use my friends Drill Press. How do you recommend I make the holes for Screws that will secure the fan to the wall. Why would I need to flash the edge with a torch? And what do you mean by mask both sides?

 

[WoodButcher]

Plywood is fine, be sure it is thicker than the pilot bit protrudes from the bell or you'll drill into the bed of the drill press.
For the screw holes I use a 5/32" or 11/64" and run though an old fan as a template, again the double stick tape. The 5/32" is better for rubber screws, if you use the metal "fan screws" that look like these make the hole a little larger (hog it out after drilling straight through w/ the template fan using the same bit. Drilling a second time w/ a larger bit may start cracks) Use a hand countersink to set the screw. A machine screw is alot less compicated, drill 5/32", 6/32 x 1-1/4" or 1-1/2" panhead w/ a nut for a 25mm fan. I prefer the rubber screws as they damp the vibration to the plexi.
Flashing the edge will eliminate the white sanding marks and make it clear like the surface. Be careful w/ the torch, too long in one spot and your piece is toast, or modern art depending on where you live.
If you have it practice w/ scrap, if not I would advise buying a small piece at the depot or Lowes to get a feel for cutting plastics. It is not hard to do but you'll feel better about cutting into your case after.