Top Exhaust fan

[Blac]

What are some tools I can use to put a clean 80mm hole in the top of a case? I need it for a top exhaust fan.

[daveleau]

I have used a hole saw bit for my drill. It works wonderfully. The 3" hole saw for use with a drill will cut a perfect hole for a 80mm case fan. Be sure to get the METAL cutting hole saw because the wood one will NOT work. Believe me, I have tried.

It looks like this except it must be one that cuts metal (including the arbor, it should be $25-$30) Be sure to get one that matches the chuck size of your drill. The 3" saw usually has an arbor with the larger chuck size: http://www.internationaltool.com/milwholesawkits.htm

Another good tool is a Dremel. It is like a hobbyist's super tool. http://www.dremel.com/html/home_fr.html

You will also need a small normal drill bit to make holes for mounting the fan. This seems to be the hardest part because there is little room for error and drill bits like to walk on sheet metal. You can use a hammer and nail for this as well, and it may be more accurate, but I have never tried this method.

Dave

[skuz]

If you use a 3" hole saw with a drill (like I did), HOLD IT TIGHT.

Else it will do like it did with mine and land on the other end of the basement.

I was amazed. (and amused)

[Knothead]

I strongly recommend using a floor standing drill press for any bit bigger than 3/4".

Any machine shop, engine shop, etc. will have one. I say 'floor standing' because a benchtop model won't allow enough room to get your box under it. Good luck!

[JimG]

Yes, hole saws in anything but a drill press can have interesting (and potentially dangerous) results. My preferred method of cutting 80 mm fan holes is a drill and a jigsaw with a metal cutting blade. I use A LOT of masking tape to cover the entire top of the case, then carefully mark the cut. Using a drill with the appropriate drill bit, I make a hole every 90 degrees of the circle. Once that's done the jigsaw cuts the rest. I clean it up with a file or my Dremel.
While a hole saw is probably the better tool here, I don't have the large drill press required.

[davidamarkley]

I just used a plain old Dremel tool w/ cut-off saws. Just used a compass to trace the circle and cut it out. Then I centered the fan over the hole and drilled out the bolt holes for the fan to be mounted, and voila! Top case fan! BTW, most people put there fans so that they blow out/exhaust the hot air from inside the case. Where as, I made it an intake fan and blew cold air from outside the case directly onto the CPU HS/F. And let me tell you, the Cpu temp dropped about 10-12 degrees Celsius!! And the system temp went down about 8 degrees!

So, when you have you hole cut out, do a test to see which way works best for you...

Good luck!

David

[Zidane]

i hate to say it but my father owns a garage, i have access to all those tools plus a blow-torch with a plasma cutter (that is used for cutting fine straight lines,if you have one, you could use it,it makes a better cut then you think a torch would and it doesnt let huge globs of melted metal) i am very good at drills i used a holesaw aswell when making a hole for my fan 3" i used a portable drill similar to a cordless but runs on AC current, (you must have very strong arms and a good grip,to hold the case and drill, i used my father's Vice to hold the case) but a dremel with a carbon or diamond circular blade would do good too (i recommend a diamond) or you could just take the plasma cutter off the propane/Oxy lines and put the original blow-torch head and valve setup back on the lines and melt a huge hole in the case,i dont recommend that,i only do that when i work on my car frame,or my motor-cycle frame. but if you need anytips im here just email me sharker1_chris@hotmail.com
i must get my 1971 dodge dart sport fixed. i hope,im in the restoration process. i currently have $3,000 in repairs and parts,and supplies (since my dad is a mechanic i have to work on the car myself,but i get to use the tools)

[tarpat1]

He's back!

[Idigguns]

Best and easiest: Hole saw (I use a regular drill).

Second: Jigsaw with a 32 tpi blade (could be very difficult to make tight radius cuts though).

Third: Dremmel with fiberglass cutoff wheels.

Can't even imagine: Torch.

Basically it depends on what tools you have available to you, and if you're willing to buy the tools you need. It can get very expensive if you have to buy everything, however, if you'll be modding alot, then it'd definitely be worth it.

[Idigguns]

Originally posted by tarpat1
He's back!

Ha ha ha Hey Zidane, what ever happened with that dual-PC anyway? I'd really like to see some photo's of that! Seriously though, you have some interesting ideas. What else have you come up with?