What is the best way to cut a clean hole for a fan?

[ChuckvB]

What is the best way to cut a clean hole for a 80mm fan in a case?

 

[mechBgon]

Probably the most foolproof method for a typical home user would be a bimetal holesaw. Guaranteed size, guaranteed roundness, guaranteed position. If you do this to a panel you've removed from the case, be sure to firmly clamp it down using wooden blocks and clamps, so it can't spin on you and injure you.

I've used fine-toothed sheet-metal blades in a small electric jigsaw. It's not too hard to cut a 120mm hole, but the tight radius of the 80mm holes made it pretty hard for me. Some hand-finishing with a hand file helped it look nice and round. You could accidentally cut too large of a hole this way, however, and then your face will look like this ---->

 

[Drewpy]

Best: Pay to have it done by professionals.
Better: Bribe professionals with beer (make sure they drink it after cutting your case)
Way Above Average: Use a hole saw with a drill press (deburring afterwards)
Above Average: Use a hole saw with a hand-held drill
Marginally Above Average: Jig saw
Average: Dremel with cut-off wheels
Marginally Below Average: Nibblers (your hand will HURT afterwards, but its a clean cut)
Bad Idea: Blow torch
Really BAD Idea: Blow torch and forgetting to take your components out of the case first.


Hope this helps!!

 

[mechBgon]

Dude, you left out "daring the local Army Reserves to demonstrate how accurate their howitzers REALLY are."

 

[Drewpy]

I live in Canada

Having twenty people attack my case with a rusty nail won't accomplish much.

But now that you've started me thinking...

WORST Idea EVER: putting Osama Bin-Laden in your case, and calling Pres. Bush, and telling him.

 

[CubicZirconia]

I just cut a 120mm blowhole in my lian-li pc-65 with a dremel and it turned out beautfully. Large holesaws tend to be expensive, if you can borrow a dremel for free they work fine (although it will take longer than a holesaw, I think the same quality can be achieved).

 

[everman]

Holesaw, then use a dremel to get rid of any sharp edges.

 

[ChuckvB]

Thanks guys, I just built a HTPC from the AVSforum site (Custom facia and LCD to match the rest of the AV/ stereo equipment) and I didn't want to botch up the custom case. Being it was a desktop the only normal place for the fan was up front, but that was block by the Aluminum facia. So a blow hole on top is the plan. PS LMAO on the blow torch idea, I'll bet some fool has tried that, probable the same gene pool as the guy who tried to roller blade off the roof on to the rail and missed it so painfully.