I am going to put a small 60 mm fan on the side of my case for extra air intake... So what tools will I need to cut the circle for the fan? For the mounting holes I assume I just use a drill or dremel tool...
I'd recommend using a bigger fan than a 60mm one. Those don't move much air for the noise they make, and since you're cutting your own hole there aren't any size restrictions. Use a 92 or 120 mm fan and you'll probably 3-5x the amount of air at the same noise level.
Panaflow 120mm....use the 7v trick and it will move more air at lower rpms.....use a drill press if you can and a 4" hole saw...oh yea, grab some cutting fluid if you can. Hope that helps and ask away if needed!
I think the easiest one to use is a drill with a cutting bit -- not sure if they come in a 120mm size, but there's not a whole lot else that's as easy to use. Dremels are nice -- and after using both, i still prefer the drill for circular holes in metal sheets. Definitle might want to get some cutting fluid -- you don't need a whole lot -- but the difference it maes on the life of your cutting bit, your drill and the cleanliness of the hole is well worth it.
Do you guys recommend cutting out a full circle for the fan, or just drill a bunch of smaller holes that make a circle? If I drilled a whole bunch of smaller holes then I wouldn't need to buy a grill for it... I'm just wondering how much air they will restrict...
for best flow and least noise with a 60, cut it all out. If you don't have a hole-saw or dremel, a nibbling tool (nibbler) will do the job neatly, effectively and cheaply albeit a bit slower. You can find them at RadioSmack for about $10. I've used all 3 methods and each have their uses.
Definitely cut out the whole hole and get a grill...in my opinion, drilled little holes will not let in as much air as a grill and you don't want that...unless you do...like if it's just for looks or something...cuz 60mm fan?
At tolerable noise levels, you will only get like 30 cfm and you can get much more with an 80 or 92mm fan. But then again, you might have an extra 60mm fan and you might not want to spend any money...in that case...don't listen to me. =)