<< One more quick question, how much smaller should i make the hole (in comparison to the fan). Like if i want to use 92mm fans, should i use a 88-90mm hole saw?? >>
You want the hole to be about 4-6mm smaller than the fan, this will provide plenty of clearance for airflow while making it virtually impossible to get fingers past the grill to the sharp edge (this way you don't have to dress the hole). Like dew042 mentioned, always use lubricant when cutting into metal with metal--best to have a small dish of oil to dip bits/saws into, and don't be afraid to peroidically stop, clean and re-dip. You will want to drill a 1/16-1/8" pilot hole first, trust me. Finally, drill into the exterior surface, this puts "slag" (whatever) under the fan, again saving dressing. Looks real nice.