How to Get a 120mm blowhole on top ?

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ReNaGAde

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I recently purchased zebronics bijli and have modded the sidepanel and have made two 80mm intake holes on the acrylic sheet. To complete the mod i would like to have a top 120mm exhaust hole cut out on top of the cabinet. This cabby has rivets to hold the chassis and the top panel is not removable. So How should i get this done ?

TIA
 
Will the people at metal cutting shops be able to provide a clean cut.....? , I got my sidepanel cut by a dremel and it wasn't very smooth. Had to cover it up with some u channel molding.
 
^ Thanks will go hunting for a shop that has a hole saw tomorrow. The cabby doesn't have a removable top panel so i will have to lug the whole cabby to the metal workshop. :@. Will a dremel with a suitable cutting disc also make do ??... as then i can call the metal guy home and get it done.
 
ReNaGAde said:
^ Thanks will go hunting for a shop that has a hole saw tomorrow. The cabby doesn't have a removable top panel so i will have to lug the whole cabby to the metal workshop. :@. Will a dremel with a suitable cutting disc also make do ??... as then i can call the metal guy home and get it done.
Click to expand...

I looked for a 120mm (approx 4.5") hole saw all around Mumbai and couldn't find one...you get the 80mm fan hole saw easily. The quotes I got for the 120mm hole saw were around 1.8K (which also were not readily available in stock...and they all said they will import it on paying advance).
I went ahead and bought one from the US...cost me around 1.2K

Anyway, let me know if you find one locally and the price.

FYI...a 120mm fan hole is easier to cut using a dremel than the 80mm fan hole....so give it a try first with the dremel if you don't want to make that investment on a holesaw for a one time mod.
 
I doubt i'll be able to find a hole saw in the kind of shops here . Will go ahead with the dremel only and add some u-channel to give a clean look.

The fan setup I've decided on the bijli is:

1 X 120 mm Low cfm intake

2 X 80 mm Low cfm intake

1 X 120 mm 69 cfm exhaust - back panel

1 X 120 mm 69 cfm exhaust - Top blowhole

Is this ok ?
 
check out my rig snaps of the water mod used a heller hole saw 102mm 4"
got it locally for 1.5k

Check out some good hardware shops i am sure they will be have it.
And its so easy to do u just need a slow rpm drill and u can do it yourself at home.
 
A 4" or a 5" hole saw is easy to get....saw some for Rs. 350 too locally..and also some that came in a complete kit...problem is getting a 4.25" or 4.5" holesaw which is the most ideal for a 120mm fan hole.

I'd still recommend you to stick with the dremel if its only a one time mod...trust me a 120mm fan hole is way easier to make than an 80mm fan hole using a dremel.

farookh said:
check out my rig snaps of the water mod used a heller hole saw 102mm 4"
got it locally for 1.5k

Check out some good hardware shops i am sure they will be have it.
And its so easy to do u just need a slow rpm drill and u can do it yourself at home.
Click to expand...
 
The tough, really crude way-

The sheet metal on Zebby Bijli is quite thin.

Do this on an empty cabby with everything including the psu, taken out.
You may need someone to help you- like holding teh cabby steady while you work on it- unless your are good with your Hands+feet+legs. :P
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Mark out the inner side of the fan frame using a 120mm fan and the four mounting holes- using a pencil.
Take the fan off and finish the circle made into a smooth, round circle using a template or some other means.

Take an Electric drill and drill bits for metal works(even a hand drill will do- will help to tone the arms. :P)

Use the right size drill bit for drilling the mounting holes.

Use the drill and drill bit of choice and drill holes along the inner side of the circle marked- so that the drilled hole doesnt cros the line.

Use a metal file to smooth out the pointy edges left after the hole part has been drilled along the inner periphery and the inner metal piece knocked out.
In case a gap is left between two holes or some extra pointy part protrudes, a good quality wire cutter/nipper can snip the small strip of metal left between the holes before you start filing.
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Big drill bit= less holes to be drilled = more rough finish or more filing
Small drill bit= lots of holes to be drilled= easier to file ina circular fashion and a smoother finish.

Try not to break any drill bits- take it easy and don't lose patience and don't apply too much pressure while drilling.
Let the drill bit cool frequently before drilling again.

You may mask the area with some masking paper/plain paper+joker gum before you begin so as not to spoil the top surface while working.

Done with lots of free time, finesse and patience- this can give an almost as good a finish as a hole saw and maybe better than a dremel/jig at times. :ashamed:

That was a lot of hard work. :P
 
BIKeINSTEIN said:
Take the fan off and finish the circle made into a smooth, round circle using a template or some other means.
Click to expand...

bah use a cd or a dvd :P
 
Thanks for the effort bikey.....! Thats a well thought out 'jugaad' method will consider if i don't get proper hardware
 
dremel is the best choice.. the metal shop guys use primitive ways of cutting metal.. they cud evn go to the level of using a chisel

dont "gas cut" sheet metal..

u cud try cutting more than the 120 dia.. n use a fan grill to cover the cut..
 
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