Modding Case Side Panel with fan - Page 3 - Overclock.net

*repo_man* · 06-30-08

Quote:

Originally Posted by aznkorean

Yeah, that's also one reason I want to do this, for the experience. Well, I'm pretty sure I can find a hole-saw bit tomorrow, when I go to work. But, it's probably only going to be about 1 1/2" (for door knobs). Is there any way to make a hole 4 1/2" with that? And, what else do I need to do in order to make a clean hole?

No. Holesaws are one size each. If you have a 1 1/2" holesaw, it makes a 1 1/2" hole. Lol.

Aside from the holesaw I would suggest a rounded edge bastard file (for metal). But you are doing the acrylic, I would think at least tape to keep the cut clean at start, and maybe some sandpaper to smooth out the hole (240-400grit I'm assuming). Take my advice FWIW on the acrylic, I haven't worked with it much.

aznkorean · 07-01-08

Quote:

Originally Posted by repo_man

No. Holesaws are one size each. If you have a 1 1/2" holesaw, it makes a 1 1/2" hole. Lol.

Aside from the holesaw I would suggest a rounded edge bastard file (for metal). But you are doing the acrylic, I would think at least tape to keep the cut clean at start, and maybe some sandpaper to smooth out the hole (240-400grit I'm assuming). Take my advice FWIW on the acrylic, I haven't worked with it much.

I know it makes a 1 1/2" hole, but I'm thinking you could trace the bigger hole and then cut it with the smaller holesaw. I imagine it would be extremely hard to make a perfect circle, I was wondering if there was a technique to do that.

So how do I make sure I get a clean cut on the acrylic? What's a rounded edge bastard file?

Syrillian · 07-01-08

Quote:

Originally Posted by aznkorean

I know it makes a 1 1/2" hole, but I'm thinking you could trace the bigger hole and then cut it with the smaller holesaw. I imagine it would be extremely hard to make a perfect circle, I was wondering if there was a technique to do that.

So how do I make sure I get a clean cut on the acrylic? What's a rounded edge bastard file?

It would be rather difficult after the first hole. One could cut a "Petal-design" as there needs to be a sturdy center-point for the hole-saw. It is possible to do what you are asking, but it may be tedious and time-consuming... but maybe not.

If you were to do as you intend, then a smaller hole-saw or forstner bit (<edit> a forstner bit will not work as well on metals and alloys) will do the trick, but you will need to start in the middle and work your way outwards in a concentric manner.

These are small files. The flat one is sometimes referred to as a bastard-file

You could use a set of files similar to those to clean the hole up.

Since you are cutting on metal or alu (?) this may not work... it does with acrylic, but I dunno about metals and alloys.

*repo_man* · 07-01-08

I think trying to make a larger hole with that 1 1/2" holesaw would be much more trouble than it is worth. The "petal" design that Syrillian mentioned would work though. I think he's referring to something like this.

That is from wastedtime's Azure mod, but that's the idea.

As far as the file. The bottom file in Syrillian's picture is a bastard file, its a flat bastard file. A rounded one just has a, well, rounded edge. Like this (| rather than a flat one that is ||

aznkorean · 07-01-08

Cool. I like this learning experience

. So for the petal design you just leave the excess metal/acrylic? It might cut down the air flow, but it's better than nothing. I'll probably draw it out on paper and mark it on the side panel before I start cutting.

Can the holesaw cut through metal? My dad said that it can't... then, are there different types(like ones for wood and metal)? And, once I get the hole finished how do I attach the fan to the side panel?

Syrillian · 07-01-08

Quote:

Originally Posted by repo_man

I think trying to make a larger hole with that 1 1/2" holesaw would be much more trouble than it is worth. The "petal" design that Syrillian mentioned would work though. I think he's referring to something like this.

That is from wastedtime's Azure mod, but that's the idea.

As far as the file. The bottom file in Syrillian's picture is a bastard file, its a flat bastard file. A rounded one just has a, well, rounded edge. Like this (| rather than a flat one that is ||

As Repo posted, that is the idea. To completely remove a larger section you could group the individual cut-outs closer, then cut the parts of the material that connect them. You would end up with an irregularly-shaped opening, and that is where the bastard-file comes into play (no offense if that was already known to you) .

aznkorean · 07-01-08

Oh, ok I got it. Now, will the acrylic crack if I don't take precautions? And do I just drill holes for the fan mount?

Syrillian · 07-01-08

Acrylic is brittle compared to some other plastics (poly-carbonate), and most platics are tedious to work with.

Drill bits crack the acrylic if they are not sharp enough, the pitch of the tip is not acute enough, too much pressure is applied, or any combination thereof.

You can use regular wood-bits, but there is a chance that either the entry or the exit wound will chip a little.

You could use acrylic bits, but (as contradictory as it sounds) wood bits will do the job, but more care and patience ought to be exercised.

For mounting fans, I abandon the typical mounting hardware, and use nuts and bolts that pass-through the fan and the panel itself. Imho it is inadvisable to have a mounting system that is comprised of metal and plastic counterparts as the latter may quickly be stripped by the former. I have had some success using the standard fan hardware, but I (and perhaps it is just me) had problems with a clean mount that had any longevity.

*repo_man* · 07-01-08

Quote:

Originally Posted by Syrillian

Acrylic is brittle compared to some other plastics (poly-carbonate), and most platics are tedious to work with.

Drill bits crack the acrylic if they are not sharp enough, the pitch of the tip is not acute enough, too much pressure is applied, or any combination thereof.

You can use regular wood-bits, but there is a chance that either the entry or the exit wound will chip a little.

You could use acrylic bits, but (as contradictory as it sounds) wood bits will do the job, but more care and patience ought to be exercised.

For mounting fans, I abandon the typical mounting hardware, and use nuts and bolts that pass-through the fan and the panel itself. Imho it is inadvisable to have a mounting system that is comprised of metal and plastic counterparts as the latter may quickly be stripped by the former. I have had some success using the standard fan hardware, but I (and perhaps it is just me) had problems with a clean mount that had any longevity.

In other words - tape off the cut, drill slow, and use bolts for the fan.