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What's the best tool for cutting blowholes.

if your drill is pretty good (high enough rpm and power, 3/8 inch bit) you can try getting a holesaw attachment, will cost you about $20-30 for one larger than 80mm. I have heard someone say he just went ahead and cut an octagon with the dremil and I think I'm going to do that (sounds simple with a good template sketched on teh case and a cut piece of black rubber hose to line the edge of the hole after I cut it) rather than invest in a good drill just yet.

Of course, you can always get a huge freaking laser to do it.
 
I use a bi-metal hole saw attached to my drill to cut blowholes. Be sure you wear safety glasses.
 
I used my dremel and a tungsten bit. Cut the hole using the side of the bit like a router. Then used a sanding wheel to smooth and make perfectly round. Time consuming, but it works good and is accurate.
 
Just to add one more method. I used a sabre saw. I used masking tape to protect the panel and then drew my template hole right on the masking tape. Drilled a 3/8" hole within the cut-out area, to start with the sabre saw blade. Cut the hole with the sabre saw and finish off by using a file on the cut edge.

This worked very well for me and looked professional when completed. Best of all, I already had these tools and didnt have to buy expensive hole saw bits or a dremel.
 
Thanks everyone... I already have a drill and a hole saw so I just took the top off my case... clamped it down to a piece of scrap and used the hole saw. Went pretty smoothly, although it took two battery charges on my drill. Looks great and seems to have lowered my case temp about 7 degrees.
 
The dremel will work fine. I used a jig saw to mod my case. You can also get a hole saw for your drill if it's powerful enough.
 
well a 78mm hole saw bit at Home Depot only cost me $12.99... I don't know how much the drill bit adapter is because I already had one.
 
jasonja is absolutely right. A case modder's site is the last place you want to buy something like a hole saw. Go to your local Home Depot, Lowe's, OSH, Ace, True Value, etc. You'll pay much less. As I recall, a 76mm Black & Decker hole saw and mandrel ran me $18.
 
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