How do you cut a round hole in plexi-glass ?

jose

Platinum Member
Oct 11, 1999
2,078
2
81
Hi everyone, I'm thinking of getting a case to mod.
I'd like cut a 120mm fan hole in the front of the case. Cutting the metal hole is no problem, but the case also has a plexi-glass front plate to it also. So how do you cut a round hole w/out shattering the plexi-glass ?

Thanks for the info.
Regards,
Jose
 

Tiamat

Lifer
Nov 25, 2003
14,068
5
71
If you have access to a milling machine, use a circle cutting tool (swing arm with blade, affixed to a drill bit) and set the milling machine to go SLOW - like 1 rotation per second.
 

computer

Platinum Member
Nov 5, 2000
2,735
2
0
What size hole? Just use a hole saw if the hole isn't too large. I use one of those spiral cut roto zip tools for larger holes in metal. They are pretty expensive though and may not be worth it to cut only one hole. MCM Electronics and Harbor Frieght Tools used to have "adjustable hole cutters" or "adjustable circle cutters" for 5-15 bucks. They are not hole saws, but radius type cutters. They'll cut wood and plastic, and thin sheet metal.
 

fibes

Senior member
Jul 19, 2003
833
0
0
Originally posted by: jose
Hi everyone, I'm thinking of getting a case to mod.
I'd like cut a 120mm fan hole in the front of the case. Cutting the metal hole is no problem, but the case also has a plexi-glass front plate to it also. So how do you cut a round hole w/out shattering the plexi-glass ?

Thanks for the info.
Regards,
Jose

I used a dremel. It takes awhile, but I think it's the safest bet.
 

HardWarrior

Diamond Member
Jan 26, 2004
4,400
23
81
Plexi is brittle, so if you use a hole saw be very carefull. If you have a choice go with Lexan.
 

jose

Platinum Member
Oct 11, 1999
2,078
2
81
I've shattered plexi-glass before w/ a hole saw. I'm trying to make a 120mm fan hole in the front of a AMS 1006 case. It already has a 120mm fan, but the
front benzel (1 layer metal + 1 sheet of plexi) don't have any holes. Anyway not enough to let the 120mm fan breathe.

Regards,
Jose
 

HardWarrior

Diamond Member
Jan 26, 2004
4,400
23
81
Well, you could take it to a local metal fabrication shop and have it cut for you. That's the easiest way and will yield pro results.
 

fibes

Senior member
Jul 19, 2003
833
0
0
Originally posted by: HardWarrior
Well, you could take it to a local metal fabrication shop and have it cut for you. That's the easiest way and will yield pro results.

What's the fun in that? If you have a dremel, it should be fine. Just take it nice and slow. It took me approx. 20 minutes (with a few breaks in between) to make my 80mm hole. My Antec Lanboy's plexiglass is very thick. It had to be atleast 1/2" thick. That's probably why it took so long to make the cut.
 

HardWarrior

Diamond Member
Jan 26, 2004
4,400
23
81
Originally posted by: fibes
Originally posted by: HardWarrior
Well, you could take it to a local metal fabrication shop and have it cut for you. That's the easiest way and will yield pro results.

What's the fun in that? If you have a dremel, it should be fine. Just take it nice and slow. It took me approx. 20 minutes (with a few breaks in between) to make my 80mm hole. My Antec Lanboy's plexiglass is very thick. It had to be atleast 1/2" thick. That's probably why it took so long to make the cut.

You're right, I didn't consider the "fun" aspect of it. I spent $400 on a case with factory cuts because I wanted it to be as close to perfect as possible. Just my hand and a dremel wouldn't have yielded results like that. 1/2 inch? Wow! Is the sheet secured with rivets?
 

Zap

Elite Member
Oct 13, 1999
22,377
2
81
I've used a jigsaw on many plexiglass cuts. Just use a fine tooth blade and go slow.