How to cut a hole in a case

[Bill in SD, CA]

What do I need to get to cut a hole for a fan in the side of my case.

Never did this before so I don't know.

Do they have sheet metal hole saw attachments for a drill?


Thanks,

Bill

[Martoch]

Jigsaw perhaps...maybe even a dremel depending on the thickness of the case. I've never modded, just what I would think of using. I'm sure someone will be along shortly to correct me.

[OuTpaTienT]

Dremels work good if you got a steady hand. Or a hole saw if you have one big enough. Ya could put a block of wood behind the metal to keep the saw from binding up.

The only time I put a hole in the side of my case I used a large drill bit to make the four rounded corners then I think I used a jigsaw to cut from hole to hole. Then just a file to smooth out the cuts. Worked fine.

[JPMiller]

Ok if using a hole saw follow these basic rules to keep from destroying your case panel.
remove the panel and use heavy masking tape, (NOT duct tape) to fully cover the side you will be drilling on then cover the area on the other side where the hole will be drilled through to with tape as well, then tape a couple "buffer" layers of newspaper to that side as well.
You want to preferably use a drill press and not a just a hand held electric drill.
use something just larger than your side and rigid... (preferably wood that you dont mind drilling into) to support and backup the metal.
Drill slowly and let the blade do the cutting.
I use a round fine finish file to take off any burrs an smooth the edges.
Dont forget to lay out and drill the screw holes as well ...following the same steps for the hole. I personally use a very slightly larger drill than needed, and I use soft rubber washers on outside (at head of screw) and between the fan and the panel to buffer the fan and reduce vibration and noise.
good luck and take your time... if you rush or cut corners you will regret it.

[crystaldragon]

Holesaw for a drill? Sure in 1/8" steps from 1/2" up to over 6".

If you are going to use a hand held electric drill a holesaw will do the trick just fine. The use a 1/4' drill bit in the center to keep them centered. Pick one with fine teeth and don't use too much pressure. Just enough for it to cut, that will help keep it from grabbing the metal. Be sure to put down a piece of wood for a backing surface and clamp the metal you ar drilling through securely.

If you have access to a drill press even better. You can use an adjustable hole saw (less expensive). Just be sure to watch how fast you feed the drill into the metal and of course be certain the metal can't spin.

There are several other ways as well. A nibbler is a good choice too. Just drill a pilot hole, insert the head of the nibbler and start squezing the handle. They are pretty useful for cutting all sorts of shapes out of metal and not nearly as hard to control as a drill or saw.


Here is a link to a nibbler at directron. So you have an idea what one looks like and how they work.

[Omardeth]

best way is to go to you local lowes, homedepot , ace , osh or any good hardware store and buy a hole saw . It is the BEST way to do it . it will give you a super clean round hole .

a jigsaw/ dremel works if your cheap but you will have to have a VERY steady hand to get a nice hole . a good power drill and a hole saw will do it the best .

here is a LINKEE to sears . this is a wood one but you should be able to get one for metal at a good hardware place . but it gives you an idea of what your looking for .

you can get them in kits or buy them for the size ya need . just make sure they have the arbor with it . if it doesn't make sure u get one with it . a 3" hole saw is perfect for a 80MM fan , 3 and 1/2 " for a 92MM fan .
HERE is a kit for an idea . HERE link to a kit i found on ebay . it is for wood but the kit is way cheap . a case door is very thin so they should work but if you get the ones for metal it will work better .

good luck

[TKP]

drememl is super hard to do by hand, get a hole saw, theyre worth the investment

[linear1]

One more vote for holesaw, plus here's a nice tutorial (JPMiller pretty much nailed it, but here's the same story with pics)
http://linear1.org/gm/archives/00000148.php

[thekingofpain]

Jigsaw (finetooth blade) and masking tape---simple effective and cheap---cheap jigsaw (10-15$?) might cost less then the metalcutting holesaw blade and arbor, plus you can use it to cut a 1000 things other then a single 3" hole in your case...

[TKP]

well a lot of the holesaw sets come with diffent sizes, we have an old ghetto one thats all rusted, but it did a pretty good job on my friends window (plexiglass)