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Expanding acrylic holes for larger fans

post #1 of 3
Thread Starter 
I'm using an acrylic case and im looking to expand some 80mm holes up to 120mm holes to facilitate bigger fans in some needed areas (water cooler for CPU and something to pump more air through the HDD cage).

I've successfully cut acrylic holes before using a dremel and will be acquiring a blow torch to polish the holes, my big thing is making sure I end up with 120mm circles and not a sad looking oval of some sort.

Facts about the case,
  • The Case Has melted previously under about 800 rpm from the dremel
  • The layers I'm considering cutting are about half an inch thick
  • The holes I'm planning on expanding have been polished previously

Any advice pertaining to how I should do this is greatly appreciated.
post #2 of 3
Without access to a CNC mill I'd either make a jig or get one of those "Oops" hole-saw kits that uses a smaller hole-saw as the pilot drill in a regular hole-saw. Cut halfway from one side, finish through from the other.
APU what?
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AMD A8-3850 Llano(FM1) Gigabyte GA-A75-UD4H 4x G.Skill 4Gb DDR3 3x WD 
Optical DriveOSMonitorKeyboard
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APU what?
(13 items)
 
  
CPUMotherboardRAMHard Drive
AMD A8-3850 Llano(FM1) Gigabyte GA-A75-UD4H 4x G.Skill 4Gb DDR3 3x WD 
Optical DriveOSMonitorKeyboard
LG DVD Seven64 LG 19"LCD / Panny 42"Plasma Logitech Cordless Elite 
PowerCaseMouseMouse Pad
Antec main, Rosewill aux Rosewill Logitech MX700 Couch cushion 
  hide details  
Reply
post #3 of 3
If it's an acrylic case, it's probably 3/16" or 1/4" acrylic. Dremel is no fun for cutting plastics. Use a jigsaw with a fairly large size tooth blade for cutting plastics. Put down blue painter's tape on the case side so you don't chew it up with the jigsaw running on it. Mark your hole accurately with a black ball point or a thin Sharpie marker so you have a narrow but easily seen line. Cut just a little inside of that line. You want to be very close, maybe nick the line a little, but don't go past it. Get a large curved file for finishing it up. Use long file strokes with very little pressure, moving the file along the cut line to keep it from digging in any one spot too long. Take off just enough material that the line is gone. Finish up with some sandpaper.

If you're really adventurous, flame polish the edges once you've sanded them. Use a mini butane torch. Try it on a piece of scrap first, obviously. Keep the flame moving at all times. Just pass it over the edge several times until it begins to get shiny. Don't overdo it or it will bubble.
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