Quote Originally Posted by Movieman View Post
Didn't read enough to see how big a hole your doing but if say 80-120mm the key is in clamping a thing(1/4"-3/8") pice of wood on both sides of the metal to be drilled and if aluminum a sharp holesaw will go thru it like soft butter.
If a 120mm hole(4 1/4" inch hole saw works fine,Home depot,$25.00 ) You really need to make sure the piece is clamped down well and your drill( not cordless) is a perfect 90 degrees to the work and then lock your arm and shoulder into place and drill at medium speed.
TWO hands on the drill at all times.
If a 4" hole saw locks it will whip your arm like a tornado hit it but I've done this thru SM steel cases and they are like 56 Buicks..You just have to do it right and be carefull.
Good Luck.
Hi MM,

Actually, all I was planing to do were four 1 inch holes in the mobo, largely because of peer pressure to start cleaning up the wiring. Actually, this is not even a material issue because the cables are still going to be a royal mess, as you will see.

I have a new 1 inch bi-metal holesaw. I also bought a round file to finish off the mess I'll make.

Other than that, the only experience I have was on old throw away cheap steel cases, and I made an oval hole in one and a jagged edge hole on the other that looked like a hole saw lol

I'm sure aluminum is easier to work with, but skill and experience is an issue.

The mitigating factor is that the mobo sits on top of any mess I would potentially make anyway.

Thanks. I need the luck.