Best way to make very large hole in cabinet

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MrAl
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Re: Best way to make very large hole in cabinet

Post by MrAl » Tue Jan 19, 2010 2:51 pm

Janitor Tzap wrote:MrAl,

Who cares what the cut out looks like. :lol:

We want a picture of the case with the fan mounted in it.
{So we can critique your work!} :lol:


Signed: Janitor Tzap

Hi again,


Janitor:
Ha ha, yeah i guess i should take some pics for later reference too.
Isnt the main point though how well it cools the inside? :smile:

Robert:
I should have realized that the white background would be deceiving, take a look at the
next pic i am attaching below. It's clearer too. Those things that look like dimples
are actually holes but the white background makes it look otherwise. They were some
pre-existing holes.

John:
Yes a laser cutter sure would be nice.
Yes, lots of good ideas, and i still have some fans to install yet so i'll be trying other methods too.

All:
I'll try to get some nice pic's tomorrow of the case and the fan. The fan lights up with green
curved 'arms' as they did an interesting job on the placement of the four LEDs and also the
blade design when they made this fan.
As far as cooling, it seems to be doing a great job. The small 80mm fan is like hot, still, summer air next to
this 90CFM 120mm fan which is like the North Atlantic wind (he he). Seriously though, it really forces the
air into all areas of the case. The small 80mm fan also had much of it's port blocked because they
used small holes instead of one big hole which is the right way to do it. How much better is it? I am
so glad you asked... :smile: After running for a few hours, here are the results:

1. Graphics card
Before: 54 deg. C, After: 42 deg C.

2. Hard drive
Before: 42 deg C, After: 37 deg C

The graphics card is right in line with the blades so i expected a lot of change there, but the hard drive
is on the other end of the case so i didnt expect much there but i got more than i expected. That area
was going to be the subject of another fan installation but im still considering various places to mount the
fan for that.


A much better pic of the piece that came out of the hole:
Image
LEDs vs Bulbs, LEDs are winning.

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reloadron
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Re: Best way to make very large hole in cabinet

Post by reloadron » Tue Jan 19, 2010 2:59 pm

Well that's it. You are now MrAl the Case Modder! Congrats on that MrAl as it looks like things went well with the project. :smile:

Ron

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MrAl
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Re: Best way to make very large hole in cabinet

Post by MrAl » Tue Jan 19, 2010 4:23 pm

Hi Ron,

Glad to see you joined the thread :smile:

Yes, this hole gave me a little experience in making these fan holes in PC cases with what
i had on hand. The only part i did not like at all was the noise when cutting between the
16 holes. The hole panel acts like a giant speaker which seems to act like an amplifier.
Next time maybe i'll bolt it to something, if i do it this way again that is, to try to stop
the intense vibration.

Wish i had an oxy/'cetalene torch! That would take about 2 minutes. I've cut through
half inch steel with those faster than this thin steel.
LEDs vs Bulbs, LEDs are winning.

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reloadron
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Re: Best way to make very large hole in cabinet

Post by reloadron » Tue Jan 19, 2010 4:46 pm

To my way of thinking I believe this was the best part:
Yes, this hole gave me a little experience in making these fan holes in PC cases with what
i had on hand.
Like you had the objective and kept thinking about your available assets. Then after kicking around ideas made a decision and moved on it. The only fan holes I have made were for a load bank I built and it was easy as it used 80mm fans so I had a 3" hole saw and went that route. Much easier than having to deal with a larger fan.

Ron

Robert Reed
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Re: Best way to make very large hole in cabinet

Post by Robert Reed » Tue Jan 19, 2010 5:27 pm

As to mysterious holes-Ah Soo!
I think the cutout shows the quality of cut as the case should be the mirror image of it.

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Lenp
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Re: Best way to make very large hole in cabinet

Post by Lenp » Tue Jan 19, 2010 6:00 pm

How about using a pattern of smaller holes sized to match hole saws or punches you already have?
Use a cad layout for optimum accuracy and appearance. There may be a little restriction but if the holes are close together it may not matter.

Sabre sawing the opening, as mentioned, will also work and there is plastic grommeting (split clear tubing may also work) as edge trim that can be applied to cover the raw cut edge. A decorative expanded metal screen (finger guard) could also be installed over the cutout or maybe even a crochet hoop could be used as a frame!

Len

OOPS!
I responded before I got to the end of the posts!
Well, rather than remove the post I'll leave it as "food for thought"!
Len

“To invent, you need a good imagination and a big pile of junk.” (T. Edison)
"I must be on the way to success since I already have the junk". (Me)

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MrAl
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Re: Best way to make very large hole in cabinet

Post by MrAl » Wed Jan 20, 2010 3:03 am

Hi again,

Im going to try to get some pics today of the finished case.


Ron:
Yes that is how it happened. Also factored in was the fact that it would be nice
to try that method and since i already had the tools to try it that way first i
thought that would be the logical first step. It did come out better than i
thought (the hole that is, and it's shape).

Robert:
Yes almost, but one thing i may not have mentioned yet is that after i cut out the
hole piece i finished up with a small sanding drum, which made the panel cutout
much much cleaner, with no real jagged edges. So the cutout will look like the
hole piece but much cleaner on the edges.

Len:
Not sure what you mean about the smaller holes. Do you mean all around the entire
diameter?
Yes i was thinking about that plastic edge grommeting but now i see that after using
a small sanding disk grinding briefly over the sharp edges of the hole, it works
pretty well for cleaning up the hole edge and then once the fan is attached it is
even better. Nothing left to cut the fingers pretty much.
LEDs vs Bulbs, LEDs are winning.

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MrAl
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Re: Best way to make very large hole in cabinet

Post by MrAl » Wed Jan 20, 2010 11:26 am

Hi again, here are the photos:


The first three here are 'sales' photos, so you can see what the fan looks like to begin with:
Image

Image

Image


These next four are the actual install:


Not running (also see upper small set of holes, that's where the 80mm fan goes):
Image

Not running:
Image

Actually running, with ambient lights on also:
Image

Actually running, with all ambient light sources turned off (night view):
Image
In this last pic, ignore the bottom green "V" shape as that is just some of the cords lit up, and ignore
the far left side as that is just part of the wall lit up.
LEDs vs Bulbs, LEDs are winning.

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Janitor Tzap
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Re: Best way to make very large hole in cabinet

Post by Janitor Tzap » Wed Jan 20, 2010 11:42 am

Ok, {Scratching head.}

Ah,
why did you mount the fan on the outside of the case?
Is there a problem where you can't fit it inside, without hitting something?


Signed: Janitor Tzap

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Re: Best way to make very large hole in cabinet

Post by MrAl » Wed Jan 20, 2010 12:49 pm

Hi again,

There are lots of wires running all over the place inside there right near that fan, and besides
it doesnt matter that it is outside instead of inside, and it doesnt take up any room inside
that way. Lots of people do it this way too. This fan is one inch thick.
LEDs vs Bulbs, LEDs are winning.

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Janitor Tzap
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Re: Best way to make very large hole in cabinet

Post by Janitor Tzap » Wed Jan 20, 2010 4:16 pm

MrAl wrote:Hi again,

There are lots of wires running all over the place inside there right near that fan, and besides
it doesnt matter that it is outside instead of inside, and it doesnt take up any room inside
that way. Lots of people do it this way too. This fan is one inch thick.
Ok,
Just seemed a bit odd.

Also, you have this computer sitting on the floor?
{Under your desk?}
If this is so.....
I'd be careful not to kick the fan by accident. :lol:


Signed: Janitor Tzap

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Re: Best way to make very large hole in cabinet

Post by MrAl » Thu Jan 21, 2010 7:10 am

Hi again Janitor,

As usual thanks for the tip. With this computer however i have it sitting with the fan toward the wall,
with the body of the computer rotated 90 degrees from the way most people orient their computers
(the face of the computer case faces to the east, so the side with the fan is away from the user).

Still, now that you mention it i think i should get a fan guard for it anyway. Right now if you stick
your fingers back there you'll hit the fan blades :smile:
Any ideas where to get just a plain ol' fan guard at reasonable cost?

Thanks and take care...
LEDs vs Bulbs, LEDs are winning.

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Janitor Tzap
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Re: Best way to make very large hole in cabinet

Post by Janitor Tzap » Thu Jan 21, 2010 8:49 am

If your going to have the fan facing the wall.
Make sure you leave a minimum of 6 inches between the wall and the fan.
Other wise your defeating purpose of the fan.
By having the expelled warm air get drawn back in through one of the other air inlets on the case.
Also, make sure that the warm air can escape upward from under the desk.
This is simple.
Just have the desk pulled away from the wall about an inch or two.

DigiKey has all kinds of them. :smile:
Standard wire grill.
Plastic grill.
Or plastic grill with replaceable filter pad.
Price is reasonable as well.
$2 for the most expensive, to .80 cents for the cheap wire grill ones.

I'd check with the local computer repair/builders too.
120mm fans have become fairly standard now.
So, I would think you should be able to find them locally without much trouble. :)

Some of the higher wattage ATX power supplies went to the larger 120mm fan.
See if you can find a dead one that you can get the wire finger guard off of it. :wink:


Signed: Janitor Tzap

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MrAl
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Re: Best way to make very large hole in cabinet

Post by MrAl » Thu Jan 21, 2010 9:57 am

Hi Janitor,


Thanks for the ideas.
All my old power supplies ( have quite a few now ha ha) all have 80mm fans too bad.
My newest one has 120mm but i still need that one :smile:
I'll check out Digikey.
LEDs vs Bulbs, LEDs are winning.

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Re: Best way to make very large hole in cabinet

Post by Janitor Tzap » Thu Jan 21, 2010 8:23 pm

Ok,
No problem.

Hmmm......
It maybe a little bit late in asking but...
While you were working on the side panel for mounting the fan.
Did you dust out the rest of the case?

I try to dust out my computer cases every 6 months.
Because the dust and fur really builds up in just that short of a time.
I have to remove the front face plate, and really vacuum it out good.
We have two pups with fine white fur, that gets into the front intake vents clogging them.
Thus, this is will restrict air flow through the case.
And you will see that this the same area that the hard drive is mounted behind.
:wink:{Hint}
You don't need cans of compressed air, or an air compressor.
But a small {wood handle} soft bristle paint brush,
and a vacuum with a hose.
Just remember to ground yourself to the case while you dust, and vacuum it out. :wink:


Signed: Janitor Tzap

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