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Cutting holes in side panel


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I have what seems to be either plastic to a Plexiglas side case (screwed to a metal frame which attaches to the case, so you can pull the sheet off) and I was wondering if I could drill two 80mm holes into the plastic/plexi along with screw holes and directly attach fans to it. Would this be feasible?
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pictures would help. But from your description, sounds fine. It would have to be a circle the 4 holes for screw at each corner, the distance between the holes is 80mm. Make sure you buy some dust covers for it though.


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yes it is feasable, but I have to warn this. Cutting plexi/lexan is tough to do well. You need very high speed and fine teeth to cut it (if using a hole saw). It is very easy to crack if too much pressure is applied, or if the saw pinches in the cut , the torque will crack it as well. There are a few here who have done a ton of modding, look for CyberDruid or MKMods and see if they can help via the PM system here.

EDIT: PM'd the two of them for you, hopefully they will visit and add insight to your mod.


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It helps to take a piece of scrap wood and drill the hole first. Then clamp this to the plastic with a backing piece to sandwich the plastic. This will help keep the piece from cracking. I find I can run a sharp holesaw in reverse and melt right through most plastic. This is less agressive. For the mounting holes if you can afford it get the right (acrylic) drilling bit (3/16"). It will have a sharper angle and different edge to it that goes right through instead of pulling the plastic (and possibly cracking it)


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whilst on this topic, I've been thinking of doing the same to the aluminum side panel on my Silverstone. Is the same method good for cutting metal panels?
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A sharp hole saw will be fine for that aluminum side panel. If its new and sharp , it will cut nice and quick thru aluminum. You should clamp it down to some wood first though. That aluminum is really thin and will bend like nothing. I would then drill a 1/4" hole in the panel (or whatever your hole saw arbor's drill bit is) first. Dont use the hole saw for this, us a seperate drill bit. Then put holesaw in drill , clamp piece to wood and I would use bursts of speed when using the hole saw. I work with metal and I have always found the burst method really works with hole saws.