Finally off to drilling holes for top rad grill:



BTW, few tips I got for drilling here (without thread, to easer fit bolts down in rad) and on sidewalls/enclosures with thread cutting there as well:
  • There was no need to buy dremel head for drills. Maybe partially it's because I was too lazy to clean insides of dremel with air from metallic shards, so it always ran at max rpm-s, maybe partially because of too little weight/hard to keep steady, but after few drills all the rest were done by borrowed normal drill. Much easier/more pleasant experience.
  • Learn how to re-sharpen drill bits. They get dull very quickly, when drilling steel case. Dremel's sanding stone makes it very easy. (You can look for reference how drill bit head looks when new, or just remember to sharpen it at slight angle, not just from center to sides, but also each side at slight angle to “screw in”. Put dremel with sanding stone on stable surface, secure it well with hand and sharpen with drill bit in another against it)
  • Puncture first center point for drill not to jump around in the beginning of drilling (don't worry too much about it. Spray paint can can fix a lot of mistakes). Also be careful with small diameter drill bits, they break rather easy. Cost very cheap though.
  • Thin walls of case and disk enclosures aren't too good for making good/long/secure thread in them, as such short thread in thin wall can be easily broken by screwed in too strongly bolts/spacers. (don't be too scared of that, you can bolt-on nut from another side of wall to secure it and dremel it down thinner. Result will be just 1.5-2mm thicker)


Oh, almost forgot to add, that had to additionally dremel off a bit tips of tools-free mounting handles for top fan motor and blades to not touch them and be able for fan to spin freely:



Few extras in this post:



My bolt painting contraption (for spraying paint on already bolted on nuts on the sidewalls I used piece of paper with punctured small hole above nut)



Future drain fitting (CF+female-female threaded multi-transfer base+cap) and fill port (fill port+cap+90deg non rotary angle+3/8”ID-1/2”OD CF(I thought that 1/2-3/4 used elsewhere won't fit here, hence used two smaller fittings and piece of tubing from fill port till reservoir. BTW, I used same method for cutting hole for fill port as for holes for fittings at back of case. First with small disk (you get several of such from dremeling other parts of case ) dremeled in star shape + center, then finished with standing stone bit. Wears down sanding stone rather fast though.



Here you can see unfinished fan splitters. I need to cut them smaller and bolt on to case wall. Soldered in usual way – power and ground together, rpm tach wire from first fan. First I wished to just borrow soldering gun from my colleague, but he offered to even let solder himself. Who am I to not agree on that, not lazy? -Of course I agreed on this offer