Originally Posted by pioneerisloud
So pretty much what I'm hearing is to go ahead and try the styrofoam (its black already anyway)...and if that doesn't look too good, maybe I should consider cutting the covers? Anybody have experience cutting them suckers? My dad works at a local steel shop (they have every steel tool imaginable), will anything there do the job easily and more accurately?
I don't know what tool you should use to cut em. Just put the fan you have on top to mark off where to make the cuts. All you'd have to make is 4 cuts total, 2 for each cover. The cuts are just straight line cuts, no corners or turns or anything fancy. You could probably get a decent enough cut from using a hacksaw though so just ask your dad what he thinks you should use. I'm sure he'll have something at his shop to suggest to you.
EDIT: I'm not positive but an 80mm should fit without much, if any, room at the top and/or bottom of the covers so you shouldn't have to worry about that. Just cut the middle of both of em so you have 4 pieces and glue it altogether.