Cutting out stock fan grills

[agfkfhahddhdn]

I have a case (Rosewill Legacy) that has three 80mm fan mounts on the back. For reference: http://www.rosewill.com/Mgnt/Upload...2542-Cm[95c8aed1c16640e5b76bb083f3a0c0ef].jpg

As you can see, the stock grills are pretty restrictive, so I'd like to cut them out, but I'm not sure what to use. My first instinct was a holesaw, but the grills are square, and this would leave a bunch of little dangly bits in the corners. The case is also aluminum and I'm worried the holesaw would bend it. My second thought was just a Dremel, but I left my Dremel at home 400 miles away and I don't want to buy another one. Any other thoughts? Is there a hand saw that might work?

Thanks!

 

[JeffMD]

Dremel... with everything outside of the case of course.

 

[agfkfhahddhdn]

Dremel... with everything outside of the case of course.

Thanks. That's what I was thinking but wanted some 3rd party confirmation in case I was overlooking something.

While I'm here, does anyone have a suggestion on how to orient the three 80mm fans (i.e. intake vs exhaust)? Keep in mind that the PSU has a 120mm exhausting through it.

 

[Essence_of_War]

Yeah for those kind of grills you'll need a dremmel.

If you've got the "swiss cheese" type ones, you can often get away with tin snips.

What does the intake look like in that case? Usually the best results for most cases is to try to build strong front-to-back airflow. If you have a couple of intake fans, 120mm/140mm, on the front, I'd orient those 80mm ones as exhausts.

 

[agfkfhahddhdn]

Yeah for those kind of grills you'll need a dremmel.

If you've got the "swiss cheese" type ones, you can often get away with tin snips.

What does the intake look like in that case? Usually the best results for most cases is to try to build strong front-to-back airflow. If you have a couple of intake fans, 120mm/140mm, on the front, I'd orient those 80mm ones as exhausts.

There are none, the only fan mounts are in the rear. A lot of compromises come with a $40 case.

 

[aigomorla]

Easiest solution is called a Nibbler... Faster and cleaner then a dremel, cuz its like punching out the grill.

Other option is to goto a hardware store and get some avation snips.
Make sure u get the one that cut straight, or bends to the outside, and not inside or it the cut end may scratch on a fan impeller blade.

 

[agfkfhahddhdn]

Thanks, I think I might go the aviation snips route, they're only like $10 at Home Depot. I also don't have much metal at all to cut through given the design of the grills.

Also, the three 80mm fans in this case combined push about the same CFM as the single 120mm in my PSU, so I think I'm going to make them all intakes. Should give it a little positive pressure to help keep out the dust.

 

[aigomorla]

if its your first time buying avation snips...

they come in 3 different cuts..

inside... where the metal is slightly bent inside..
outside.... where its bent slightly outside.
Straight... where it cuts straight...

Also i would spend about 15 dollars - 20 dollars on avation snips..
The cheap ones will cramp your hand out, also avation snips can cut almost any case out there except the thick Japanese Steel ones they used to use on OLD cases.

 

[doyll49]

For clean cutting grills out of cases I use a nibbler. They work in confined areas better than snips.

Aviation snips are compound action snips and come in left cutting, right cutting and straight cutting.

 

[JeffMD]

Keep in mind that the PSU has a 120mm exhausting through it.

Keep in mind that you should never rely on your psu fan to do anything accept cool the psu. A modern psu won't even run the fan until some load is put on the psu, and unless you are maxing out the psu the fan will run at low speeds.

 

[BonzaiDuck]

Easiest solution is called a Nibbler... Faster and cleaner then a dremel, cuz its like punching out the grill.

Other option is to goto a hardware store and get some avation snips.
Make sure u get the one that cut straight, or bends to the outside, and not inside or it the cut end may scratch on a fan impeller blade.

Ha! You beat me to it!

The only problem I see with a dremel cut-off wheel arises from the slotted aluminum destined for cutting. The irregular surface could cause the wheel to skip or bind. So it would need a light and very steady touch.

 

[agfkfhahddhdn]

if its your first time buying avation snips...

they come in 3 different cuts..

inside... where the metal is slightly bent inside..
outside.... where its bent slightly outside.
Straight... where it cuts straight...

Also i would spend about 15 dollars - 20 dollars on avation snips..
The cheap ones will cramp your hand out, also avation snips can cut almost any case out there except the thick Japanese Steel ones they used to use on OLD cases.

What would you recommend for this application? Straight?

I did some brief research and people suggested that Wiss made the best snips, would you agree with that? They're only $10 because they're on sale.

Keep in mind that you should never rely on your psu fan to do anything accept cool the psu. A modern psu won't even run the fan until some load is put on the psu, and unless you are maxing out the psu the fan will run at low speeds.

Fair enough. There's really no good way to orient the fans in the back of the case, though.

 

[aigomorla]

Wiss is a very good brand... and yes i would go with straight, as straight cuts is what u would probably want the most...

Straight would be a flushed cut.

 

[doyll49]

What would you recommend for this application? Straight?

I did some brief research and people suggested that Wiss made the best snips, would you agree with that? They're only $10 because they're on sale.



Fair enough. There's really no good way to orient the fans in the back of the case, though.

The difference is not just for cutting straight, left & right. There are at least 10 different aviation snips that I can think of.
Straight cut metal with left side up and right side down equally
Left cut metal with left side up and right side flat
Right cut metal with right side up and left side flat

Straight have handles aligned with cutters
Left and right have handles angled up from cutters

To cut a corner requires a left and a right cut .. unless it is a flat piece of metal that can be turned and worked from both sides.

Honestly, a nibbler is the best tool for removing case grills.

YouTube has videos showing how they work

 

[PhIlLy ChEeSe]

I cut the mesh out of one of my cases before, then mounted the fan outside the case, an air nibbler? He's not doing production line assembly, a good nibbler costs a couple hundred bucks. I think the hole point is to do a cheap mod, not reinvent the God Damn Wheel.

 

[ClockHound]

I cut the mesh out of one of my cases before, then mounted the fan outside the case, an air nibbler? He's not doing production line assembly, a good nibbler costs a couple hundred bucks. I think the hole point is to do a cheap mod, not reinvent the God Damn Wheel.

So... this isn't the moment to suggest he pickup a CO2 laser at his local high power optics shop?

 

[doyll49]

I cut the mesh out of one of my cases before, then mounted the fan outside the case, an air nibbler? He's not doing production line assembly, a good nibbler costs a couple hundred bucks. I think the hole point is to do a cheap mod, not reinvent the God Damn Wheel.

Whoa there big fella!:thumbsdown:
Quite cussing, read what has been said. It's not what you think. :thumbsdown:
There is nothing about getting an air nibbler. You are the first to mention air nibblers. :biggrin:

The only nibbler referenced in this thread is the simple inexpensive hand nibbler BonzaiDuck posted is the best way to trim out grills in cases. For perfectly straight lines a guide can be clamped onto case to run nibbler against.



I use a Klein No. 76011B

 

[aigomorla]

So... this isn't the moment to suggest he pickup a CO2 laser at his local high power optics shop?

waterjet works better :biggrin:

 

[MrTeal]

waterjet works better :biggrin:

Probably want to power down before using it.

 

[agfkfhahddhdn]

OK guys, got the waterjet, it cut the grills out perfectly. Should I let the motherboard dry before I turn it back on or just cover it in rice?

 

[ClockHound]

Rice, but with some 4000rpm Sans Aces as intakes. Oh and remove the fans from the cooler & gpu. Snap. Crackle. Pop.

:biggrin:

 

[PhIlLy ChEeSe]

Sorry!
I assumed you meant air nibbler, I used one in a body shop for work. :awe:

 

[Mnpctech]

I will use Hole Saw Attachments. I've posted a DIY guide here, http://forums.anandtech.com/showthread.php?t=2454089&highlight=mnpctech

 

[doyll49]

I will use Hole Saw Attachments. I've posted a DIY guide here, http://forums.anandtech.com/showthread.php?t=2454089&highlight=mnpctech

Make sure you are setting down and have a defibrillator handy before you look at the price of 120mm and 140mm saw cups.
I have used them many many times and I would never try using anything over about 50mm in a hand drilll! Exotically in an 18v or 24v one. When the saw cup grabs the metal when ti goes through the drill torque is dangerous!! Just ask those who have experience with them.

Use a drill press with case on wood and clamped to drill press table.

A jig-saw works fine. Just be careful not to cut outside of circle. Better to have to file a little out for perfect circle than over-cut. Again, clamp a piece of wood on the back to help stop the vibration .. also use the finest tooth blades you can find.

 

[Mnpctech]

Hey doyll, Yes, the hole saw attachments can be spendy. I also cant stress enough about having a powerful power drill, so you have enough torque to spin the hole saw without it binding up.

btw, thanks for the referral from Austin, he was searching for grill, for his CM Wave case.