Best Tool For Cutting Fan Holes?

[DeludedGuy]

I need to cut one or two 80mm round holes in my CoolerMaster Aluminium Side Panel. Or maybe one 120mm hole.

What would be the best tool for the job?

[Shogun]

Dremel tbh. Cuts through aluminium like butter. Just mask well and it should be alright, aluminium scratches very easily.

[Shogun]

Problem with the hole saws is that you need something to clamp the panel to, and it seems whenever i clamp a panel down it creates marks/bends the panel as some force has to be put on the panel with the holesaw.
I can get a perfect circle with a dremel, you just have to practice and mark out well before.

[Flash]

remember for a 80mm hole you would bneed a hole of around 74-77mm

[PeteSmith]

Use a 80mm hole saw like DeludedGuy said, with a multispeed drill, put some grease around the case where the hole is going to cut, this will stop any burning or scarring of the case paint or finish. Also don't drill straight through the case in one go, start the hole on one side then turn it over and finish the cutting through from the other side, this helps prevent any burring of the case (turned up edge around the hole). Did it myself a few weeks ago, made a great job, honestly wouldn't be able to tell the difference from a factory job. You can pick up fan grills and filters from any decent pc shop to finish the job. The hardest part was finding screws to fit that had a smooth rounded head.

[unrealrocks]

Use a 80mm hole saw like DeludedGuy said, with a multispeed drill, put some grease around the case where the hole is going to cut, this will stop any burning or scarring of the case paint or finish. Also don't drill straight through the case in one go, start the hole on one side then turn it over and finish the cutting through from the other side, this helps prevent any burring of the case (turned up edge around the hole). Did it myself a few weeks ago, made a great job, honestly wouldn't be able to tell the difference from a factory job. You can pick up fan grills and filters from any decent pc shop to finish the job. The hardest part was finding screws to fit that had a smooth rounded head.

Got it in one - although if you have problems with claming etc. get a thick bit of scrap wood and clamp the side to that (usually needs to be smaller than the case side or it'll squash/interfear with the edges), that'll give you a good finish

Also buying a holesaw is cheaper than buuying a dremmel if your just doing a couple of holes, lol.

[TeePee]

Holesaw is probably best for cutting a perfect hole. A jigsaw is the cheapest way to quickly cut a pretty good hole as good as your skill with the blade (use good quality blades specifically for metal). A dremel would do it, if you are a masochist, but not nearly as well as the other tools. Good for cutting the heads off of nails though...

[Shogun]

Got it in one - although if you have problems with claming etc. get a thick bit of scrap wood and clamp the side to that (usually needs to be smaller than the case side or it'll squash/interfear with the edges), that'll give you a good finish

Also buying a holesaw is cheaper than buuying a dremmel if your just doing a couple of holes, lol.

But first you have to have a drill Plus you can get dremmels very cheaply now.
Teepee wanna bet?

[TeePee]

Yes.

[GAteKeeper]

I have tried all the methods - a proper arbor (hole saw) is the best esp. if you use a peice of wood at the back and a pillar drill

GAteKeeper

[richman]

Hole Saws are the best tbh get a good reinforced one that is graded for alui and u will be sorted. Dont get 80mm tho get 74-77mm

- Richman