ATTN: Case Modders!

[Deagle]

I've been experimenting and found that if I take my side panel out, my cpu temp will drop 2-3C. So now I want to cut a hole and put couple fans on the side panel to help with cooling. What kind of tools would I need to complete this project? Also it'll be cool if I can cut a large square/rectangle and put plexiglass there so I can see my LEDs. :D
Thanks a lot.

[david eaton]

To make the large holes for the fans, there are several ways if doing it, depending on what tools/facilities you have.
1 hole saw in drill press/ milling machine ( my personal favourite!)
2 mark out the hole, drill small holes close together all the way round, break out the centre, and file off sharp edges.
3 drill small hole, and use jigsaw to cut out the hole.

Then use the fan as a template to drill the mounting holes.

The Chain drilling method will also work if you want to put a window in the side. Just drill all round the shape, and break out the centre piece. All you need is a drill, electric or hand, and a file to clean up the edges. A centre punch is a help to make sure the drll does not wander and scratch the finish.

[Deagle]

I definitely don't have access to drill press/milling machine. But there's Sears so can I use something like this (http://www.sears.com/sr/javasr/product.do?BV_UseBVCookie=Yes&vertical=TOOL&pid=00910104000) to make the necessary holes? If possible, please recommend some tools that I'd need and a link to each one.
Mahalo. :p

[Donn]

Whoa!! Hold off on that drill gun for a sec. Before you plug in the drill gun--you'll need a slab of wood at least an inch thick to catch the drill bit when it suddenly breaks through the metal at flank speed and bullets into the antique mohagoney desktop. . . .And before that you will need a metal cutting drill bit and a clean piece of cardboard from a box. Put the cardboard under the panel on top of the wood, it will keep the wood from scratching the panel. When you start to drill it you want to have someone hold it firmly, and you want to make a little bite with the drill gun first, just enough of a mark to hold the bit in place . . .and then back it off and press the trigger full to get max rpms, and bring it into that little bite at full speed. Don't slam it, just bring it.

If not then you take a chance on depressing or bending the area. The idea is to make a quick clean cut into the metal so that it cuts before it can depress or bend. It has to be clamped or held firmly.

If it is warped or bent a little around the edge and you get the temptation to smooth it out. . .get a thin piece of cloth like a an old teeshirt and put the panel on a hard flat clean surface, metal preferrably, with the teeshirt under it--remove the card board for this, and cut a piece of the tee shirt out of it (probly should double it over) to wrap around the hammer head (tape it), or lay it on the panel--no metal on metal.

NOw this is all on the premise that you don't have a machine shop handy and you are doing it yourself in the garage or the basement...not on the dining room table, of course. . . :D

:cool:

[Abbadon]

The prefered tool for casemodders has long been the dremmel, or so was my understanding. Ideal for cutting holes, filing raw edges and sofort, while beeing relatively cheap and very easy to use. (http://www.dremel.com/html/home_fr.html)

[pave_spectre]

Dremels are an outstanding tool. the sheer number of accessories made specifically for dremels and their lookalikes is incredible. And they are slightly more versatile than regular drills.
Just be careful if you decide to go for a cheap lookalike. With hand tools like dremel you need something that can sustain power while cutting without overheating. My cheapo arlec can only cut without binding at full speed but gets too hot to hold in a matter of minutes. So no cutting case windows in one go with that thing.

[Donn]

I agree with Pave, and especially if you have to buy one. A metal cutting drill-bit would be a whole lot cheaper too. . . maybe $2.00 USD ? :)

Edit: Dremmels are great little tools, I happen to have one of the originals circa 1958 (I forget the model #), also great for self-dentistry. . .all those little pointy accessories--great for doing your own root canal jobs, really. :eek:

[Reid]

I use a sheet metal nibbler like this: http://www.ehobbytools.com/index.html?target=p_33.html&lang=en-us

They are not very fast, but you get some hand exercise. You need to drill a hole for a starting point.

[Deagle]

Hmm, from the responses a dremel sounds good. The problem is where can I get it for cheap but still does the job? Sears or Home Depot maybe? Please give link to products that you recommend.
Thanks.

[PrntRhd]

Here is a whole Dremel kit for variable speed, the works, $72:
http://www.amazon.com/exec/obidos/tg/detail/-/B00006JSPB/103-8844445-9253445?v=glance
And a simpler, smaller kit for $49:
http://www.amazon.com/exec/obidos/tg/detail/-/B0001408UM/103-8844445-9253445
Reid's nibbler is $14, but be advised you want to use gloves unlike his link's pic.
Also wear eye protection with both methods, Dremel discs have been known to break up, nibblers send metal flying.

[cyber_surfer]

I drilled a top blowhole and a side blowhole in a Sonata case.

I got instructions from a modding book. Measure and make sure your PS and Optical drive will have clearance if working on top. Use blue painters tape on the surface you will drill and mark on it. It will also protect the paint around the edges of the cut so you will have minimum painting to do.

I used a 3 inch metal cutting drill in a heavy duty slow rotation drill. I clamped a small piece of 2x6 under the cut to drill into. This method gives perfect holes with little effort. You have to remove all equipment from the machine and clean it out well before putting anything back.

After the large hole was done I held an 80mm fan over it to mark out the four holes for mounting the fan. Small metal cutting drills for this. My wife was able to hold the case itself okay but the removable side gave her a problem when the 3 inch bit would grab. Consider clamping the whole side down or having somebody strong hold it for you.

I used standard chrome grills over the fans. They where very quiet verses some of those fancy cutouts that caused high pitched sounds on top of the fan noise.

I read an article that suggested rounding off the edges on the inside of a side blowhole fan and mounting a 3 inch plumbing connector to focus the air on the CPU (a duct which is recommended by Intel for their prescott processors to cool them down).

Not to difficult or time consuming a project.

[FastLearner]

Another question about dremels. I have never seen one until I followed the links given here, but it appears to be easier to use than drilling 50 holes and then punching out and having to file sharp pieces of metal. How does this thing actually work for drilling large holes into a computer case? ...or is this just a tool to use for sanding and or smoothing the inside edges of the hole? Oh yeah, and while I'm at it...is it okay to use just a normal piece of fiberglass inserted over/under the case? I'm having a hard time picturing how you all can get the fiberglass to stay in place, but drilling sounds like a chore if you're drilling through fiberglass.

In case you haven't noticed, I am not a handy man! But if such a project is easy enough, then maybe I would try and tackle it myself. Thanks.

[Grumper]

Dremels run at very high RPM`s and are only really good to smooth and elongate rough edges. Your best bet is to use a 3" hole saw [Home Depot] and you will get a perfect hole. Now a 3" hole saw requires a 1/2" drill chuck and you better use a variable speed drill and go nice and slow to medium speed and read what ------cyber_sufer says------ I have an old Sears Dremel tool and there is nothing like it when it is needed--this is NOT one of those times---stick with a "hole saw"