Originally Posted by Wazige
i am currently having a first go at modding an old case. but i am having trouble cutting the 1mm steel in nice shapes and nice round holes for fans. got any tips?
I think that if you really want a nice round hole the best way would be to get a hole saw. I know that some people can cut nice round holes with a dremel, but they are more experienced than me and were likely cutting through 0.8mm aluminium. I decided that it would be a waste of money to get a hole saw, but I was a bit mistaken as a hole saw attachment for a drill is not that expensive and will end up saving you time and frustration in cutting a round hole. I did end up with quite round holes, but it is not really neat enough for my liking. Also, all of the fan mounts that I have are not really visible from the outside once the panels go on.
What I did for my cutouts as they are now, is that I marked out the circle but cut a shape out smaller than the actual outer diameter. After this I rounded out the rest of the metal with the dremel by grinding and cutting and using a file to smooth it out. This may work for you as the metal you are working with is thinner than what I used.
What I drew onto the metal:
I then cut it out with straight cuts, slightly smaller than the actual circle:
Then I rounded it out to look like this:
What I did could have been done neater, but as it was first ever real use of a dremel things didn't go as well as they could have. Also, you can see in the larger plate, in the bottom hole, the cut out is round with a straight edge on the left hand side. This is because I attempted to use a jig-saw, that attempt ended badly as the jig-saw that I have can only really cut in a straight line, trying to adjust the direction ends up making a mess.
I hope that this helps you out. I do not know what powertools you have access to or whether these holes that you want to cut will be on the outside of the case or hidden somewhere inside, but if you have more questions feel free to ask.
Originally Posted by mobeious
So did u thread he holes u drilled in the case to accept the bolts?
Ah, I didn't really explain that. I didn't thread the holes in the case, I fasten the plates by passing bolts throught the plates and the case and then using nuts from the inside of the case. I haven't gotten around to making photos yet as I only woke up 45 minutes ago
but I'll do that later.