Modding steel case (cutting holes in it): Tools needed or where I could do this??

[LxMxFxD4]

I want to mod an old Antec SX1040BI by putting a 120mm fan mount on the side door. I believe it is standard .8mm (22gauge) steel. I called home depot to see if they do anything like that and they said no way. I called back to the tool rental department and was basically laughed at. Aside from spending $100 on some sort of dremel type tool with a metal bit, any recommendations? I find it hard to believe that home depot doesn't rent tools with metal bits. But maybe I am way off. I see lots of people cutting through their cases.. how do you do it?

 

[smackababy]

I used a Dremel on my Corsair 700D, and I bought the special metal cutting disks. I believe that is the only way. If you do use a Dremel type tool, be careful. It takes a steady hand not to hack the metal up.

 

[BoomerD]

I don't know of any one who rents this kind of equipment. Just go buy the Dremel and do the job.

You MIGHT be able to do it with a metal-cutting hole saw...but you're going to be spending about as much as you would buying the Dremel and accessories.

 

[ahenkel]

if you're not looking to a lot of modding and just want a couple holes cut I bet an auto body or metal shop could do it for not too much.

 

[LxMxFxD4]

Thanks for the responses. I didn't even think about an autobody shop!

A friend of mine has a dremel actually, I think I may borrow his.. doesn't have the metal disk bit however.

I did some googling and found results that said large tin snips can cut through 22 gauge (0.8mm) steel. I actually have a pair of those but that doesn't seem possible. Anyone had any success with tin snips? I'm thinking I start by drilling a hole.. once tampered out, just cut the circle with tin snips. Any thoughts?

 

[BoomerD]

Thanks for the responses. I didn't even think about an autobody shop!

A friend of mine has a dremel actually, I think I may borrow his.. doesn't have the metal disk bit however.

I did some googling and found results that said large tin snips can cut through 22 gauge (0.8mm) steel. I actually have a pair of those but that doesn't seem possible. Anyone had any success with tin snips? I'm thinking I start by drilling a hole.. once tampered out, just cut the circle with tin snips. Any thoughts?

It can probably be done, but the end results may be somewhat less attractive than desired...

 

[Kenmitch]

Why not just do stock style and use a drill bit. I doubt it would take much effort to make a pattern on paper and then just tape it to the side panel and use a sharp punch to make pilot holes. You could use any larger size bit but would be best if little fingers couldn't fit in the holes.

 

[LxMxFxD4]

It can probably be done, but the end results may be somewhat less attractive than desired...

Don't care about looks, I care about cooling. I get a good chuckle at all the nerds obsessed with the look of a steel box that sits under a desk that no woman will ever see. I mean, to each his own, but it does make me chuckle.

 

[LxMxFxD4]

Why not just do stock style and use a drill bit. I doubt it would take much effort to make a pattern on paper and then just tape it to the side panel and use a sharp punch to make pilot holes. You could use any larger size bit but would be best if little fingers couldn't fit in the holes.

I need maximum airflow. This will be an exhaust fan and needs to push that maximum cfm. I suppose I could put an even bigger fan hole on there, I just happen to have 120s lying around.

 

[infoiltrator]

There are tools called nibblers intended to cut sheet metal without distortion. You do have to drill a hole to start.
CablestoGo Case Mod Nibbler. Harbor Frieght has one, do not know how well it cuts circles. Klein Tools has one but you need more underclearance for its return spring.
These are hand nibblers. Air powered nibblers are common for body work and sheet metal shops. Electric are rare.

I would sususpect if you put a bolt thru a hose clamp then put the clamp on the dremel as a pivot, and drill a bolt size center hole, patience with a dremel would do a good job.
For the dremel you would want the .045 fiber reinforced cutting discs.

A bottom intake hole might help move air into case and force more out.

 

[Jimmah]

+1 for the dremel suggestion.

Cutting disks will cost you about 4$ for a pack of 20. Trace your pattern then trace the same pattern 1-2mm smaller inside, once finished use the side of the wheels to grind to the outside pattern. Go slowly, you don't want to burn the paint from overheating.

Oh, and us 'nerds' like things to look clean and not like a hack-job, regardless if women will see it or not, albeit my wife likes the work I do when it is clean.

 

[stahlhart]

Don't car stereo installation shops have specialized hole saws for putting speakers in door panels and such?

 

[dma0991]

I would go with a dremel that has a cutting wheel. Preferably a used cutting wheel where the diameter is smaller to allow easier cutting compared to new and larger diameter cutting wheel.

I would not use any scissor style cutting tools as they would usually leave shearing marks on the steel. Also do not cut the hole with the dremel according to the size that you want. Make the hole slightly(<1 mm) smaller than you want it to be and use a metal file to do the finishing touches.

 

[LxMxFxD4]

Hey guys, thanks all for the responses. I found this online:

http://www.youtube.com/watch?v=9iMiH8wYTDY&feature=iv&annotation_id=annotation_338411

Shows exactly how to cut a hole with a dremel.

I did try to cut this with my drill and metal snips. I basically spent about 15 mins of effort (and failure) just creating 8 pie shapes that I can't really effectively cut into a good circle. It turns out this antec case is 1mm steel, but I should still be able to use a dremel, I just gotta buy these cutting disks:

http://www.amazon.com/Dremel-456-Rei...f=pd_sim_hi_13

I dunno, I may just buy a dremel at this point, the coordless 8000 is only $62 at amazon. The guy in the video says "stay away from coordless" but that would be far more convenient I think.

 

[LxMxFxD4]

I would go with a dremel that has a cutting wheel. Preferably a used cutting wheel where the diameter is smaller to allow easier cutting compared to new and larger diameter cutting wheel.

I would not use any scissor style cutting tools as they would usually leave shearing marks on the steel. Also do not cut the hole with the dremel according to the size that you want. Make the hole slightly(<1 mm) smaller than you want it to be and use a metal file to do the finishing touches.

Hey ya, the 15/16" wheels are way cheap, and the 1.25" are about 40% cheaper than the 1.5". Does it make any difference? I'd imagine the 1.5" would last longer, is that the only advantage?

 

[BoomerD]

Hey guys, thanks all for the responses. I found this online:

http://www.youtube.com/watch?v=9iMiH8wYTDY&feature=iv&annotation_id=annotation_338411

Shows exactly how to cut a hole with a dremel.

I did try to cut this with my drill and metal snips. I basically spent about 15 mins of effort (and failure) just creating 8 pie shapes that I can't really effectively cut into a good circle. It turns out this antec case is 1mm steel, but I should still be able to use a dremel, I just gotta buy these cutting disks:

http://www.amazon.com/Dremel-456-Rei...f=pd_sim_hi_13

I dunno, I may just buy a dremel at this point, the coordless 8000 is only $62 at amazon. The guy in the video says "stay away from coordless" but that would be far more convenient I think.

While the cordless model may be somewhat more convenient, it probably won't have the same amount of power...nor will the charge last very long.
Better to buy the corded version.

Hey ya, the 15/16" wheels are way cheap, and the 1.25" are about 40% cheaper than the 1.5". Does it make any difference? I'd imagine the 1.5" would last longer, is that the only advantage?

Which ever size you choose, get the fiberglass reinforced cutting wheels. They'll last longer without shattering. I've had several of the "regular" cutting disks "explode" while in use..

 

[LxMxFxD4]

Which ever size you choose, get the fiberglass reinforced cutting wheels. They'll last longer without shattering. I've had several of the "regular" cutting disks "explode" while in use..

Ouch! I dont know anything about dremel accessories, but is this what you're talking about?

http://www.amazon.com/Dremel-EZ406-C...8525570&amp;sr=1-4

I believe the part # is ez456 but with the mandrel its called ez406. Thoughts?

 

[BoomerD]

Ouch! I dont know anything about dremel accessories, but is this what you're talking about?

http://www.amazon.com/Dremel-EZ406-C...8525570&amp;sr=1-4

I believe the part # is ez456 but with the mandrel its called ez406. Thoughts?

Not what I was talking about, but those will work very well...in fact, those supposedly will last longer than the ones I was thinking about.
BTW, be sure to wear some safety glasses.

 

[LxMxFxD4]

Well either way, I have to buy something. Buddy's 300 dremel has no cut off tools with it. I'll figure it out when I get to walmart or whatnot. I guess for now i'll just borrow his and see how it goes.

 

[infoiltrator]

SPCR has a guide using Wiss Aviation snips, right and left hand. The quality matters, the technique is a spiral cut from a center hole taking only as much metal as curls easily.Leave a 1/4 inch for the final cut.

 

[LxMxFxD4]

I did it this morning with the dremel metal bit. The 1mm steel was a real bitch to cut through. The final hole is not very good, but it is roundish! I'll post pics of it finalized after I clean it up tonight and mount the fan.

The sad part is the fan hole basically used an entire 1.25" metal bit. Lets see, 2*pi*r = ~15 inches of 1mm steel per bit. I probably used more of it than a pro would use, as the first half o my circle looks terrible compared to the 2nd half when I got the hang of it.

 

[BoomerD]

I did it this morning with the dremel metal bit. The 1mm steel was a real bitch to cut through. The final hole is not very good, but it is roundish! I'll post pics of it finalized after I clean it up tonight and mount the fan.

The sad part is the fan hole basically used an entire 1.25" metal bit. Lets see, 2*pi*r = ~15 inches of 1mm steel per bit. I probably used more of it than a pro would use, as the first half o my circle looks terrible compared to the 2nd half when I got the hang of it.

Use a half-round file and clean up the edges, (you want to make sure there are no burrs left anyway) then a spot or two of paint...cover with a fan and fan grille...and it'll be a thing of beauty.

Beat to fit...paint to match.

 

[Rifter]

dremel works great, as does a plasma cutter.

 

[pepperbegs]

Hi,

I'm reviving this old thread with a question.

Harbor Freight Tools has a Dremel clone eighty piece tool kit on sale for under $8.00 and it looks to have a power cord.

Has anyone used a cheap tool like this? What was the result?

Also, I know that hole saws and dremel type tools give less then perfect results unless you have some skills. Do you clamp the metal piece to a wood board to provide support for your work? Is there a plastic "edging product" that can clip on to cover sharp edges and imperfections?

Thanks for any input.

 

[MoInSTL]

On a tower server case I used a hole saw at the end of a drill. Just have to go slow and a sturdy piece of wood underneath helps. Made perfectly rounded holes and fans fitted perfectly. Just needed to file the rough edges some.