I want to cut holes for fans, where do i start?

[GrimReality]

This is my case:
http://www.spirecoolers.com/main/product_detail.asp?ProdID=529#
...well...kinda...the version I have I think is slightly older because the one featured here has a different front and rear fan setup than mine (I have 120mm both front and back), but otherwise its the same thing.

This was a cheap case, bought it a few months ago and it was about 60 bucks. Pretty good deal for a full tower. Of course what makes it so cheap is its lack of fancy features...like extra fans. It's got a vent on the bottom of the case that perfectly fits an 80mm fan, so I put one there, and I didn't even have to make my own holes as the vent holes lined up almost exactly to the screw holes on the fan. So that's cool. But what I really want are side and top mounted fans and unlike the bottom of the case there isn't a perfect spot for them, so I'm gonna have to make them.

My question is how do I do this? This is a pretty heavy metal case so I know I can't just cut/drill into it with anything I currently have around the house, so what kinda tools am I going to need? Also, I'm on a tight budget. That's part of the reason why I bought this case, because it was within my budget, so I don't want to shell out a lot of cash on modding it because then that defeats the purpose of buying this particular case.

What I've got planned specifically is for 3 more 120mm fans - 2 on the side door (intake), 1 on the top panel (exhaust). The 2 on the side will be centered and one top of the other, so it pretty much makes it to where one fan is at the level of the CPU and RAM while the other is at the level of the Graphics card(s). I would have done 4 out of vanity because some of the expensive high-end cases have 4 fans on the side panel but unfortunately due to the way that the HDD's mount inside there's not enough room to do 4 120mm fans on the side panel.

So help me out here, cutting holes for 120mm fans in a metal case and I need to do it on the cheap. :)

[Spawn-Inc]

first off welcome to the forums!

second i'm not sure if this is the absolute cheapest but you might try your local hardware store for a 120mm hole saw (http://www.computerpoweruser.com/images/smartcomputing/fullsize/00843400.jpg). you will need a drill with atleast 18v, you might get away with 14v. any corded drill should be fine i think. if you have a drill, jig saw with metal blade, and a steady hand. you can trace out a 120mm circle and then drill a whole on the inside then cut on the inside of the line.

[GrimReality]

hmmmm... the hole saw looks like it might work.... did a quick check on amazon for them and they look like they're in the 10-15 dollar range. That's not too bad.

I don't have a jig saw. Wish I did though.

I'll do some shopping around, got a Home Depot down the street. Before I came here I was considering just taking the side panel of my case in there and asking them for advice on what to do.

Thanks, spawn.

[Spawn-Inc]

hmm i wonder if you could do that but go to a metal or machine shop and see what they can do, they got lots of tools and i don't think would charge to much. i would tape it up and draw the cut out you want before you go so they have less work to do.

EDIT: i forgot to add metal shop

[GrimReality]

I've already got it drawn on the inside of the panel :)

But I don't know any machine shops around here.

[Spawn-Inc]

i forgot to add metal shop would do it too i think. what tools do you have?

another way that might work is by drilling around the circle on the inside and then you should be able to cut or punch the metal out then just file down the edge of the circle. it would be tedious and take longer but should give a good result.

Thats what i mean just in case.
http://img252.imageshack.us/img252/9886/holesawmz2.th.png (http://img252.imageshack.us/my.php?image=holesawmz2.png)

[Redundant]

another way that might work is by drilling around the circle on the inside and then you should be able to cut or punch the metal out then just file down the edge of the circle.
Note: don't use your fist to do this. :p

[D1337]

Note: don't use your fist to do this. :p

Unless your chuck norris :santa:

[Xtrykr]

No, chuck norris would do a back spin kick and cut a hole through it with his toe nails.

[GrimReality]

As far as power tools go, spawn? hmmm...we've got a drill...and that's about it lol. And Yeah I thought about doing it that way too with a bunch of holes all around, but I figured there must be a more efficient way than that.


Note: don't use your fist to do this. :p

Noted :P

[GrimReality]

Tried for about 15-20 minutes just to put a single 1/4" hole in the area that I'm going to cut out and I didn't even get through. Looked more like I shot it with a BB gun than used a drill on it. :hurt:

[Redundant]

Tried for about 15-20 minutes just to put a single 1/4" hole in the area that I'm going to cut out and I didn't even get through. Looked more like I shot it with a BB gun than used a drill on it. :hurt:
Try using the very small drill bits first and work your way up to the large quarter inch one. :up:

[elbarto241]

you can buy one of THESE (http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=44060) and punch holes all around the inside of the circle then use a file to close in the space in between the individual circles. \

[FuzzyPlushroom]

another way that might work is by drilling around the circle on the inside and then you should be able to cut or punch the metal out then just file down the edge of the circle. it would be tedious and take longer but should give a good result.

I've actually successfully made fan holes by pounding an awl (a nail works too) through (instead of drilling) around the perimeter of the hole, twisting the awl back and forth in the hole until the tiny bit of steel in between the holes cracks, hammering the area around the hole down flat, and filing th' 'ell out of it. If all you have is a hammer, an awl (or a nail, though your hand starts hurting after a while that way), and a file, this is a functional, albeit slow, way to make a hole.

Do I recommend it? Not really. :D

(If this doesn't confirm my user title, nothing will...hahah)

[GrimReality]

That wont work, elbarto. The closest any part of my holes will get to the edge of the panel is about 3 inches and I don't think it could even reach that far. But thanks for the thought.

Fuzzy, that's plausible but it seems like it would cause a lot of damage to the area around the fan holes due to the bending of the metal. I see you say to hammer that area back down so it is flat but I can't imagine it looked too good afterwards. However, that method is free as far as monetary cost to me (though it will definitely make up for it in time and possible smashed fingers), so I'll give it a try to see how difficult it might be.

[elbarto241]

when you are drilling, does the metal just warp around the tip of the bit and become really hot? if so the solution is simple, clamp a layer of wood behind the part where you are drilling. sounds stupid but trust me it works :D

[GrimReality]

It did warp a tiny bit, I think from the pressure of me pushing down so hard on it.

[elbarto241]

if the bit is just spinning and heating up the metal without breaking through you can: a)get the bit sharpened or buy a new one or b)clamp a piece of wood behind the surface to help support the material you are drilling through.

[slaveofconvention]

Obvious question but I'm gonna ask anyway... You ARE using a good quality METAL drill bit, right? I don't mean made of metal, I mean made to DRILL metal - a wood bit just won't work, it'll spin, get real hot, make a pimple, go blunt (and a cheap metal bit won't be much better) ..... and lots of pressure won't help, a good bit will pull itself into the metal with relatively little pressure - not to mention it'll be easier to control - not as likely to go skipping away from the desired point...