need help drilling 120mm holes on my case

[kuangs168]

hi everyone. i have an aluminum case, i want to install a radiator 120.2. so i need to cut 2 120mm fan hole on the top of the case for it. but i dont have any cutting tools, so wondering how much they cost and where to buy them. or cheaper just go somewhere have someone cut it for me?

if you recommend me mount the radiator on the outside back of the case, what i need in order to do that? i still need to cut small holes for the tubes?

thanks

 

[cronic]

you need to get a hole saw at lowes hardware or home depot or similar any hardware store. i would reccomend a 4 1/2" / 114mm hole saw. drill a pilot hole centered in the location you wish to put the hole. chuck up the hole saw and carefully cut the hole. i reccomend using masking tape to cover the area where you will be cutting. this will give a nice hole. you will want to clean the hole up with some 220 grit sandpaper and your done.

 

[kuangs168]

how much the powered drills cost? how strong they need to drill thru aluminum?

 

[Fullmetal Chocobo]

Are you going to do just this hole? If so, you might consider having it done. I got three holes put in my case for fans, and it cost ~$35. So it if the cost of getting it done by a metal working shop is cheaper than the tools, there would be no sense in getting the tools for a single job. Now if you think you might use the tools again on another case or something, that is a different matter.

EDIT: If you do end up doing your own cutting, use lubrication material. For steel, cutting oil or Rapid-Tap is wonderful. I believe for aluminum, beeswax works best. GalvanizedYankee schooled me on this stuff, so listen to what he says if he posts here.

 

[Boyne7]

what i do when i drill holes, is first i take a blank cd and use it as a template and position it where i want the hole, then i make a circle around it for the cut. i then use a small size drill bit to drill a bunch of tiny holes inside of that circle, then i use tinsnips to cut the inner circle into parts and then bend them till they break off, then i use a rotozip to cut off the jagged edges left, and use sandpaper to finish the job. its kinda tedious but it works quite well.

 

[RKS]

Originally posted by: Fullmetal Chocobo
Are you going to do just this hole? If so, you might consider having it done. I got three holes put in my case for fans, and it cost ~$35. So it if the cost of getting it done by a metal working shop is cheaper than the tools, there would be no sense in getting the tools for a single job. Now if you think you might use the tools again on another case or something, that is a different matter.

EDIT: If you do end up doing your own cutting, use lubrication material. For steel, cutting oil or Rapid-Tap is wonderful. I believe for aluminum, beeswax works best. GalvanizedYankee schooled me on this stuff, so listen to what he says if he posts here.

just go to a metal/body shop. I took my steel case to a local autobody shop and for $50 he cut a blowhole and custom side window with a plasma cutter. Also included in the price was a nice new glossy black finish.

IMHO, unless you need to buy the tools for other projects, don't waste your money.

 

[Fullmetal Chocobo]

Originally posted by: RKS

Originally posted by: Fullmetal Chocobo
Are you going to do just this hole? If so, you might consider having it done. I got three holes put in my case for fans, and it cost ~$35. So it if the cost of getting it done by a metal working shop is cheaper than the tools, there would be no sense in getting the tools for a single job. Now if you think you might use the tools again on another case or something, that is a different matter.

EDIT: If you do end up doing your own cutting, use lubrication material. For steel, cutting oil or Rapid-Tap is wonderful. I believe for aluminum, beeswax works best. GalvanizedYankee schooled me on this stuff, so listen to what he says if he posts here.

just go to a metal/body shop. I took my steel case to a local autobody shop and for $50 he cut a blowhole and custom side window with a plasma cutter. Also included in the price was a nice new glossy black finish.

IMHO, unless you need to buy the tools for other projects, don't waste your money.

I took my stuff to a stainless steel fabrication place in Corpus Christi. Did an absolutely wonderful job for $38...

 

[HardWarrior]

Originally posted by: Fullmetal Chocobo

Originally posted by: RKS

Originally posted by: Fullmetal Chocobo
Are you going to do just this hole? If so, you might consider having it done. I got three holes put in my case for fans, and it cost ~$35. So it if the cost of getting it done by a metal working shop is cheaper than the tools, there would be no sense in getting the tools for a single job. Now if you think you might use the tools again on another case or something, that is a different matter.

EDIT: If you do end up doing your own cutting, use lubrication material. For steel, cutting oil or Rapid-Tap is wonderful. I believe for aluminum, beeswax works best. GalvanizedYankee schooled me on this stuff, so listen to what he says if he posts here.

just go to a metal/body shop. I took my steel case to a local autobody shop and for $50 he cut a blowhole and custom side window with a plasma cutter. Also included in the price was a nice new glossy black finish.

IMHO, unless you need to buy the tools for other projects, don't waste your money.

I took my stuff to a stainless steel fabrication place in Corpus Christi. Did an absolutely wonderful job for $38...

Nice!

 

[Spike]

I just used a dremmel with a cutting bit. Since I did not have a good trace line the cut was kinda rough so I had to use sandpaper to get it clean looking again. The Dremmel (off-brand) kit with tons of attachments was ~$26 at Costco so I was very happy.

good luck!

-spike

 

[GalvanizedYankee]

I PMed you last night OP.

True, it is easyer to have it done but if you invest in a few simple tools, they will be used
more than once after they are embraced.

Remember, every guy should get a drill with his man card


...Galvanized

 

[hipgnosis]

I used a drill and jig saw to cut holes in my cases. The drill and a 1/2" bit to cut the pilot hole and the jig saw to cut the 120mm hole. I drew the outline of the hole on the case then covered it with clear shipping tape to prevent scratching the case....and it allows you to easily see the outline. If you don't know someone who has these tools you can pick up some inexpensive ones on ebay.

 

[GalvanizedYankee]

Well here goes, via PM I told you I'd give it my best shot so here it is.

Tools will be at the end.
You say that the case is aluminum,*if*it is a Lian Li the four pop-rivets can be drilled out and the top removed. Working the top panel off the case is easyer. Just drill the rivets with an 1/8" drill till the heads spin. With a tiny screw driver push out the rivet. Reinstall the top panel, using short 6-32 screws with nuts. Be sure and mark the inside of the top panel for front so it doesn't get reversed on reinstall.

To set-up. Tape the fans firmly, exactly where they need to be. Chuck an 11/64" drill bit in the drill motor, then carefully insert it through the mounting holes then give it a spin with light pressure, this will cause a divet where the holes need to be. Do not drill through at this time. Keep the drill motor vertical while doing this so the taped down fan is not displaced. Remove the fans, place a wooden board behind the panel to back it up. Now drill the holes through. Mount the fans suction side down with 8-32 screws and nuts. The holes should all line-up. With a pencil held at an acute angle, mark the area to be removed. The pencil mark will be made from the inside of the fan.

Remove the fans. I would screw a board to the off-side of the panel using sheet metal or wood screws. This will provide back-up. Now drill a series of 3/8" holes 5/8" away from the pencil mark. Do not use high speeds when drilling these holes, use a moderate speed. Try to keep them from over lapping but close to eachother. Remove the board. Now take a nibbler and clip the bits between the holes. The center falls out.
Now go around the hole dressing it up with the nibbler. Done.

A nibbler makes short stright cuts, about 5/16" long, so this is going to take some time.

The holes for you hoses can be done with a nibbler. Just drill a 3/8" hole where you want the hose then dress/cut the diameter with the nibbler.

Now to dress-up the holes. For the hoses, ACE Hardware(any hardware store)sells rubber grommets that will inset into the hose holes. Say the hose has a 5/8" OD. A grommet for that would fit a 3/4" or 1" hole. Buy these grommets before making the hose holes, so you can fit them.

To dress-up the fan hole, if you wish. Buy some small diameter vacuum hose, split it length wise, then fit it around the fan hole. Push it lightly to compress the rubber against itself. When you get to the joint cut it just a tad long. Butt the ends together. It will not fall out.

Using a CD for hole size is OK but it is a bit large. Hold a CD to a 120mm fan and you will see.
Using a jig-saw is not for the new power tool user. Apprehension will cause damage.

Tools.
You PMed me the battery operated tool pack link. Cordless tools are for portable light duty use. There are much better alternatives for our purposes.

From Harbor Freight. I have and use these bargain tools.
3/8" electric drill motor. Variable speed, reversable, keyless chuck. About $25.
Part#03670
Only use it at high speed for sanding, not drilling.
A 10 pack of 11/64" drill bits. A couple of 3/8" drill bits or buy a drill selection in a case.
While at Harbor Freight, buy a heat gun. They are on sale for $9.95. Part#35776
Why?? Heat shrinkable tubing, to warm up hoses for instalation, to warm up stuck heatsinks for removal, to accelerate the drying time of silicone adhesives or the set-up time of epoxy. It's a long list.
While at Harbor Freight buy a kit of files. They are cheap. Make sure to get several small rat tail files because these really are a blessing when holes don't align properly.

At Jab-Tech.com, in the tool section, buy a $8 nibbler. I send you there because it is made in Taiwan and is a good one. I just got mine last Monday. It will cut 18gauge steel(.046") or 1.5mm aluminum(.062"). Works good.

Files can be use to really dress-up your work before installing the grommets. Dressed up with a file the fan holes may not need rubber tubing to look presentable.

I like using cutting fluid when working metal. Try to locate and buy some Rapid-Tap, use it for everything but filing. A light smear of it with your finger before using the nibbler takes 40% of the effort out of the squeeze. Practice with the nibbler on the centers that were removed for the fan holes to get a feel for the tool.

Post or PM me if you want/need more. I'll post it here.


...Galvanized

 

[RKS]

Originally posted by: GalvanizedYankee
Well here goes, via PM I told you I'd give it my best shot so here it is.

Tools will be at the end.
You say that the case is aluminum,*if*it is a Lian Li the four pop-rivets can be drilled out and the top removed. Working the top panel off the case is easyer. Just drill the rivets with an 1/8" drill till the heads spin. With a tiny screw driver push out the rivet. Reinstall the top panel, using short 6-32 screws with nuts. Be sure and mark the inside of the top panel for front so it doesn't get reversed on reinstall.

To set-up. Tape the fans firmly, exactly where they need to be. Chuck an 11/64" drill bit in the drill motor, then carefully insert it through the mounting holes then give it a spin with light pressure, this will cause a divet where the holes need to be. Do not drill through at this time. Keep the drill motor vertical while doing this so the taped down fan is not displaced. Remove the fans, place a wooden board behind the panel to back it up. Now drill the holes through. Mount the fans suction side down with 8-32 screws and nuts. The holes should all line-up. With a pencil held at an acute angle, mark the area to be removed. The pencil mark will be made from the inside of the fan.

Remove the fans. I would screw a board to the off-side of the panel using sheet metal or wood screws. This will provide back-up. Now drill a series of 3/8" holes 5/8" away from the pencil mark. Do not use high speeds when drilling these holes, use a moderate speed. Try to keep them from over lapping but close to eachother. Remove the board. Now take a nibbler and clip the bits between the holes. The center falls out.
Now go around the hole dressing it up with the nibbler. Done.

A nibbler makes short stright cuts, about 5/16" long, so this is going to take some time.

The holes for you hoses can be done with a nibbler. Just drill a 3/8" hole where you want the hose then dress/cut the diameter with the nibbler.

Now to dress-up the holes. For the hoses, ACE Hardware(any hardware store)sells rubber grommets that will inset into the hose holes. Say the hose has a 5/8" OD. A grommet for that would fit a 3/4" or 1" hole. Buy these grommets before making the hose holes, so you can fit them.

To dress-up the fan hole, if you wish. Buy some small diameter vacuum hose, split it length wise, then fit it around the fan hole. Push it lightly to compress the rubber against itself. When you get to the joint cut it just a tad long. Butt the ends together. It will not fall out.

Using a CD for hole size is OK but it is a bit large. Hold a CD to a 120mm fan and you will see.
Using a jig-saw is not for the new power tool user. Apprehension will cause damage.

Tools.
You PMed me the battery operated tool pack link. Cordless tools are for portable light duty use. There are much better alternatives for our purposes.

From Harbor Freight. I have and use these bargain tools.
3/8" electric drill motor. Variable speed, reversable, keyless chuck. About $25.
Part#03670
Only use it at high speed for sanding, not drilling.
A 10 pack of 11/64" drill bits. A couple of 3/8" drill bits or buy a drill selection in a case.
While at Harbor Freight, buy a heat gun. They are on sale for $9.95. Part#35776
Why?? Heat shrinkable tubing, to warm up hoses for instalation, to warm up stuck heatsinks for removal, to accelerate the drying time of silicone adhesives or the set-up time of epoxy. It's a long list.
While at Harbor Freight buy a kit of files. They are cheap. Make sure to get several small rat tail files because these really are a blessing when holes don't align properly.

At Jab-Tech.com, in the tool section, buy a $8 nibbler. I send you there because it is made in Taiwan and is a good one. I just got mine last Monday. It will cut 18gauge steel(.046") or 1.5mm aluminum(.062"). Works good.

Files can be use to really dress-up your work before installing the grommets. Dressed up with a file the fan holes may not need rubber tubing to look presentable.

I like using cutting fluid when working metal. Try to locate and buy some Rapid-Tap, use it for everything but filing. A light smear of it with your finger before using the nibbler takes 40% of the effort out of the squeeze. Practice with the nibbler on the centers that were removed for the fan holes to get a feel for the tool.

Post or PM me if you want/need more. I'll post it here.


...Galvanized

wealth of info here. but now i am even more convinced that my course of action was the safest for me as well as those around me.

 

[Fullmetal Chocobo]

Are you like me, in that when I get a power tool in my hands, the wife gets worried?? hehehe

 

[RKS]

Originally posted by: Fullmetal Chocobo
Are you like me, in that when I get a power tool in my hands, the wife gets worried?? hehehe

yup, but she did get me a Dremel a few years ago (still like new) and i am gonna finally use it to make some modifications to my p180 and my project case in a few weeks.

 

[Fullmetal Chocobo]

Originally posted by: RKS

Originally posted by: Fullmetal Chocobo
Are you like me, in that when I get a power tool in my hands, the wife gets worried?? hehehe

yup, but she did get me a Dremel a few years ago (still like new) and i am gonna finally use it to make some modifications to my p180 and my project case in a few weeks.

Yeah, she got me one too. I ended up getting another one (the LithiumIon ones suck) later. She has come to respect my modding skills now at least.

 

[GalvanizedYankee]

Black&Decker high speed rotory tool>>>>>>>>>>>>>Dremel high speed rotory tool=Fact.

Use rapid-Tap when working with rotory files on any material(steel or aluminum).
Use with drills and hacksaws also.

Use bee's wax on the bit when working just aluminum.

...Galvanized

 

[kuangs168]

basically i just need a drill, a nibbler and heatgun, those are main power tools?

can someone list out the stuff i need to buy at local homedepot or lowes warehouse? something cheap but will do the job?