theCanadian

Materials needed:

• Paper (preferably poster board)
• Exact-o-Knife
• Access to a paint program like Photoshop (somewhat optional)
• Aluminum Flashing - Available here cheap. (use coupon code SHOP15 for a 15% discount)
• Rotary Tool with cutoff blades (like a dremel, optional)
• Masking/Scotch Tape
• CREATIVITY!!

This is the process that I used to make this fan grill.



Step 1: Pick and print your design.

Decide what size fan you want to cover up or install and place your design on the appropriate template. You can get a template here: http://www.mnpctech.com/Fan_Grill_Templates.html You will need a paint program like Photoshop to open this template. If you don't have access to a paint program you can use my template, available here. Open it using Quicktime Picture Viewer. Or if you like my design (120mm), you can get that here. Open that with Quicktime Picture Viewer as well.

Print your design out. The thicker the paper the better. I used poster board that I had cut to 8.5" by 11". Cut out the white space using an Exact-o-Knife or something similar.

Step 2: Transfer your design

Attach your cutout template to the aluminum flashing by using masking/scotch tape. Now transfer your design to the aluminum flashing by tracing the edges of your template and marking the metal. If you don't have a rotary tool just keep tracing the design with the Exact-o-Knife until you cut all the way through (will take a LONG time). You may choose to leave your paper template attached or to remove it for the next step.

Step 3: Cut it out

I chose to leave my template on for the cutting stage in order to protect the surface of the metal. Take your rotary tool (or Exact-o-Knife) and carefully cut out your grill. Take your time, any slips can scratch the flashing.

Finish up:

Remove sharp edges and burs with files or sandpaper. Drill your holes. And your done. Just clean up your work area and attach your new fan grill to your case!

Easy right?

Edit: Metal snips, or small sharp scissors, like surgical scissors, may be used in place of a dremel or Exact-o-Knife during the cutting stage. However, if you choose to go that route, be careful not to warp the flashing; it's pretty thin stuff.

radodrill

looks pretty good and certainly achievable by most people with the patience to do it right.

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theCanadian

OK I wanted to add this to the guide. You may also use sheet metal if you have it but you have to use a dremel, trying to cut with an Exact-o-Knife would take a lifetime.

gibsonnova74

I like your creativity. rep+

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xlastshotx

Pretty cool, I will definitely use this in my project... I just have to figure out what aluminum flashing is....

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theCanadian

Thin aluminum that is used for pretty much anything. Repairing heat ducts, gutters, down spouts, trash cans, etc. It is also used around lights and chimneys to keep the weather out. Cheap stuff. I have a link in the materials list that points you to flashing that is 6 inches wide by ten feet long. $5. Hope that helped.

G|F.E.A.D|Killa

if your good with metal snips you dont need a dremel

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I heard Ford is coming out with heated bumpers in 2010 so your hands don not get cold while pushing it.

theCanadian

Never thought of that. I'll add it. Actually, if you had a pair of really short and really sharp scissors...

(like the ones that give you if you've gotten stitches. Apparently it's cheaper throw away a suture kit and buy new ones than it is to wash them, so they just give them to you if you want it. If you don't have any, your going to have to severely cut yourself )

Anyway, if you have short and sharp scissors, then if your careful not to warp the flashing you could do most of your cutting that way.

rep+ for the good idea. Now even MORE people would probably do this.

theCanadian

Ight guys. I just made another grill out of sheet metal that I cut out of an old case to make a window. The process went the same. It just took a little longer with the dremel since the metal is thicker.

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ElementQKA

i think its will probably work with a can of coca cola (more cheap) ill try that