Cutting Fan Holes (How to)?

[ComputerWizKid]

I bought an old computer case from eBay an Enlight EN-7200 (Made in 1997 the first revision of the case) so it only has a front 80MM fan which I already cut out the stock grille as it was severely restricting of air flow. but the case has no back fan so I want to add one (I can only add one because it has knockouts for ports Serial SCSI Parallel ETC) I am limited to 60 MM fan size any bigger and it will interfere with the IO ports on the ATX backplate. I have several 60mm fans left over from the Socket A/462 Days and I also have the grilles to match them. So is the general idea just to trace the grille and cut a hole that size or do I make it smaller then the grille? I have a Dremel clone (A Black & Decker RTX) and I have plenty of cutting wheels so I'm prepared with tools. I know a holesaw is better but I'm cheap and I don't want to buy a tool I will use probably once plus my drill sucks.

Oh I bought such an old case for my HTPC because it has 3 5.25" bays (I could not find a modern case with 3 I have my DVD Drive and an Matrix Orbital LCD screen Which takes up 2 bays, I don't like the Built in VFD cases because most are only 2 X 16 my screen is a 4 X 20

 

[drakore]

Dremmel perhaps? every modders favourite tool

 

[bigpow]

Just don't use The Nibbler!

 

[abhong]

Home Depot or Lowes probably got the easiest solution for smaller holes...

http://www.lowes.com/lowes/lkn...Id=158168-72068-7238SB

i've heard they have bigger than 2" but his will give you the cleanest and round cuts... all else, well good luck with a hole cutting bit...

 

[thilanliyan]

I used a dremel with a tungsten carbide cutting bit to cut a hole in the top of my P180 case. It's a bit hard to do and takes time but with some filing afterwards it looks clean.

I was thinking of using a cutting wheel but they get destroyed easily.

 

[MadScientist]

Wow, deja vu. I had (have) this same case and modded it a few years ago. I managed to squeeze 2 - 60mm fans in the back, cut a hole in the side for a 92mm fan directly over the CPU, cut out the restrictive grill in the front and replaced the 80mm fan with a 92mm fan. I was able to use 3 of the holes where the front plastic fan cage attached to attach the 92mm fan.
I used hole saws for the 60mm and side 92mm fans and a dremel with a cutting wheel for the front fan. I clamped a small piece of plywood to the inside of the back when I cut out the holes to prevent it from tearing apart. Those 60mm fans at full speed sound like a jet airplane so I used extensions to connect them to a fan controller.

I used Krylon Fusion satin black for the case and front bezel and silver vinyl dye for the drive openings, the power and reset switches, and the fronts of my floppy and DVD R/W drives. I sprayed the back with crackle finish silver metallic paint.
The case has been sitting in my garage for a few years. It last housed an Epox MB and an Athlon XP CPU.
Here's some pics (yeah black shows fingerprints):
Case1
Case2
Case3
Case4

 

[BonzaiDuck]

I'm almost jealous, Mad-man. The rear chassis is especially neat.

A dremel is a b**** to use for small, round holes, as for 60mm fans. But I never plan on using 60mm fans in the chassis panels.

My biggest challenge is finding space for 120mm rear exhaust fans on recycled midtower cases. Sometimes I'm lucky to fit in one or two 92mm fans. I've used the dremel to cut 80mm fan-holes, but it's still a challenge.

The reason I favor the dremel is this: you can cut a 120mm fan hole by removing 90-degree pie-wedges, leaving a solid cross-brace of case sheet-metal. Tedious? Sure. But it provides some extra options, and a more rigid structure.

As for the nibbler: it comes in handy for finishing dremel-holes in tight corners. If you use it carefully, you can cut some precise holes, and it might even be better for smaller fan openings. But if the nibbler is the hand-operated Radio-Shack version, you will need to get some Ben-Gay for your hands to alleviate suffering on the following day.

 

[MadScientist]

To cut a hole where none existed before, I still think a hole saw is the way to go. If you want to take out a restrictive grill or make a hole bigger to put in a bigger fan than I find the variable speed Dremel, or it's B&D equivalent, with a cutting wheel works best, followed with grinding stone, and then a sanding bit.
Some people like a nibbler better. Use whatever you are most comfortable with and works best for you.

And don't forget to wear safety glasses or goggles. My daughter's boy friend had to go to the emergency room a few weeks ago to get metal slivers taken out of his eye from using a Dremel.