Cutting Holes in Aluminum Cases

[WeaponX]

Anybody got a good and clean way of cutting 120mm holes at the top of a aluminum case?

I've thought about using a hole saw, but my hands aren't that steady...

the 2nd option would be using a dremel and "slowing" cutting around the surface.

Any thoughts guys?

btw, I'm cutting these holes to mount a radiator for my water cooling setup :D.

[Doplh3]

I use a hole saw when doing that stuff. You don't need a steady hard (especially not compared to using a dremel). Works great for me.

[Unoid]

ALUM is fairly easy to cut. I used a dremel + cutoff wheel and got pretty clean cuts. with pencil used to be a guideline.

[sKiTz0]

hole saw does not require steady hands at all. The drill bit in the middle keeps it in place.

[phobos]

I also did it with my dremel.

Couln't get my hands on a 120mm hole saw.

[freecableguy]

4.5" hole saw is the correct size if you want to mount a 120mm fan. The hole created will perfectly match the inner circumfrence of the fan.

[Reflex1]

use a random CD as a template ...its exactly 120mm.

[XanderF]

Just used a compass myself to draw the whole, then a permanent marker over it as a guide.

Dremel all the way, baby! Nothing these guys can't do....

[Vassili Zaitsev]

With a hole saw is very easy, you must take a nail and make a small hole in the center of where will be the 120mm, next you take the hole saw and put the drill bit in the middle on the hole that you did with the nail and RUUUUNNN!!!

next, take a BNC Cable (coaxial) and open it for the middle and use it to hide the imperfections of the hole.


And, with a dremel, you can use a CDROM, as a5h tolds you.

[XanderF]

What kind of RPM do you need to get a hole saw to cut through aluminum, though? I've tried some before, and they just never seemed to make any progress in the case.

As to 'trim', I usually just buy PC case 'window trim' (http://www.crazypc.com/products/casemods/windows.htm#moldings) for this purpose.