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Options for making 120mm hole

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DiamondFire13

Senior member
Hi, I was wondering what options I have for making a 120mm hole in my case, are there hole saws that big, or do I need to use a jig saw or what. What would be the cheapest? What have other people done?


Thanks,
Paul
 
Drimmel tool is a cheap way to do it. It does ok, but its tough to get it to look perfect. Ive seen hole saws for drills that do a good job, you just need a powerful enough drill (my rechargable one would never hack it...no pun intended).

-MC
 
what i did was after marking it was drill holes every cm or so, took a hammer w/ a flat head and beat out the "CUTOUT"....it's a little jaggy, but i've got a grill, so you can't see it, and you can't cut your fingr on it! good luck
 
i used my dremel for the plastic, and took the case itself to a metal working shop, they did a perfect job, they have the tools for it, only cost $15
 
Don't be a sissy! Buy a dremel and do it yourself. It's really easy as long as you get high quality bits. Plus it's fun and rewarding (oh dear god I sound like an advertisement... someone shoot me please)
 
Either a dremmel or a jig saw will work fine. I used a jig saw for mine. If you want to be really fancy you can use a router. 😉
 
a jigsaw is quick, but you gotta watch out for the bottom of the saw scratching the case. dremels aren't as fast, but are a little easier to control. you also have to replace the cutting wheels often, as they tend to break/wear down quickly. a hole saw would be sweet, but they're frickin expensive.
 
Thanks guys!!!!

I am going to try drilling holes every few cm and try that method. I have an aluminum mesh filter to go over my massive 120mm fan, so looks dont really matter, and that will be cheapest.

well, it is bed time.

Paul
 
Agreed...jigsaw worked good for me. Just make sure you coat the case w/ masking tape to keep from scratching it w/ the bottom of the jigsaw. 😉
 
If you drill your holes as close together as you can, you can then wiggle the drill with a bit of side load to join the holes, then use a round file or dremel to smooth it. Center punch the holes before you drill so you dont slip.
If you use a jigsaw to do it, just put on 2 layers of masking tape over the whole surrounding area and mark your holes on the tape. That way the jigsaw won't damage the paint.
 
I have a completely different idea.Go to your local radio shack(or better yet...call'em), and see if they sell a metal "Nibbling"tool.Another source of this tool would beharborfreight.com,and look for a metal nibbling tool.

Once you have the tool, mask the case off w/tape.Wear safety glasses!Drill a small hole slightly inside the circle you've drawn on the case.Keep enlarging the hole with larger drills, or a reamer, and insert the nibbler into the hole.Every time you squeeze the handle, a small piece of metal will be removed.

When you are reasonably close to the hole size,use a rounded metal file, sandpaper on a stick, whatever to enlarge the hole to the proper size...and remove any burrs.

Mark your mounting holes for the fan, peel off the tape, and mount the fan.It's a good idea to use a metal "Grille" to protect the fingers,etc., that'll get close to the blades.

If you get too much noise from the fan,try this(I am assuming D.C.Fans).Put two fans in series and run them at 1/2 speed.They'll be quieter, and last a long time.Just be sure they are blowing in the intended direction....if not, reverse the connections to the one, or both, that are blowing backwards.
 
what kind of case do you have? As long as you don't have something like my SuperMicro 750 and 760 (which have heavy gauge steel sides)... Dremel doesn't work on those, and the nibbler... well... it takes forever and your hand gets really tired and sore 🙂
 
I am not sure what it is, it is the same one that they sell at most comp-usa stores, black one with 3-5" and 2-3" front bays. It is pretty nice, but heavy.

I think it is an older antec

Paul
 
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