Case cutting (tools ??)

[jabski]

I am looking to cut a hole for a 120mm fan to mount into the front of a aluminium case. I have a dremel multi pro but was wondering if there was a better or easier way to cut it.
Anyone who can explain what tools or methods to do this would be very helpfull :toast:

[IFMU]

Personally, I use the dremel to cut pretty much anything needed/wanted for case mods. Including fan holes.
Most like to use a drill with the special bit thingy.. lol sorry, not sure what its called right off hand.
Wow... it totally evades me right now.. hrmph.
I'm sure someone will be able to come along and give you the name of the fracking thing.
I prefer the dremel, but it is not easy to get a nice clean circle, you really need to have a good steady hand to do it and have it look decent.
Most like that other thingy I cant think of... It goes into a drill.. lol sorry
:shrug:

[rbd89]

You're thinking of a hole saw, and it makes cutting fan holes MUCH easier. Ive done both and believe me, the $20 on that hole saw bit is well worth it.

[nibble]

What shape were you going to make the hole? If it's round a holesaw would be best, it is possible to make good circular holes with a dremel but it's just too hard really, unless you're very skilled. A jigsaw with a HSS fine tooth cutting blade would be good for straight cuts or a dremel (*with reinforced disks*) would work too. Keep in mind though you won't get perfect cuts with any regular tools, you're going to have to debur and straighten the edges with a file and sandpaper. Of course if you have access to a plasma cutter or the like that would be the best by far.

[beaneh]

You're thinking of a hole saw, and it makes cutting fan holes MUCH easier. Ive done both and believe me, the $20 on that hole saw bit is well worth it.

+1

You can get a full range of Bi-metal holesaws here (http://www.shop4tools.co.uk/cgi-bin/sh000001.pl?REFPAGE=http%3a%2f%2fwww%2eshop4tools% 2eco%2euk%2facatalog%2fsearch%2ehtml&WD=holesaw&PN=shop4tools_co_uk_Disston_Bi_Metal_Holesaws_35%2 ehtml%23a10600#a10600) mate, they also supply the arbors.

[IFMU]

Yea thats it. :smacks forhead:
Knew someone would be able to name it, gawd sometimes yea just feel like a moron. lol
Most people like to use the hole saw, typically much easier than other methods.

[jabski]

many thanks for your replys. Hole saw it is :)

[serialk11r]

There's also adjustable hole saws that are meant for wood and plastic but I think they probably can go through sheet metal like aluminum. BTW jigsaw works as well ;)

[YanBooth]

Plasma cutter with a 57.5mm radius jig. If you're smart, you can very easily make a jig quite easily.
As for the plasma cutter, yeah I know thats not the kind of thing most people have lying around, you can also make a jig with a Dremel, as some have already suggested. I don't think the radius is EXACTLY 120mm, more like 115mm tops, so I would suggest going to a Home Depot, or hardware store (if you live in the US for home depot) and borrowing a tape measure and checking what is approx. the right size.

good luck

[JeffnWV]

just go down real slow with the 4 1/2 hole saw at first and hold the drill very firm/ridgid making sure you touch the surface evenly. Hole saws (especially larger ones) like to warble around if you don't be it's master ;)

If you can find a 4 5/8 or 4 3/4 hole saw they allow for the optimal air especially if there's any stand off at all ( gaskets, posts, etc)