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Hole saw

E

eternaljammer

2[H]4U
Joined
Nov 9, 2005
Messages
2,789
I want to know where and what kind of holesaw I need to drill a hole big enough for a 120 mm fan to put in the side of my case. Thanks for the help.
 
120 millimeters = 4.72440945 inches according to google.

So probably 4-3/4" hole saw or whatever's close.
 
4 5/8" diameter is what you want to use. Same size as hole in the fan frame. CD/DVD disk makes an excellent template.

A "Bi-metal" saw is preferable. But a regular one for wood will work for a couple jobs if used properly.

Here is an image what NOT to do ::



When using a Holesaw always remember to use slow RPMs. One of the biggest mistakes people make is running them too fast and burning up the work piece, the saw, or both.
 
Considering 4 5/8 Inch isn't a very easy size to find, I would go with a 5 Inch hole saw. Home Depot has one for $27.97
 
Ouch on the price. If you don't plan on doing anymore holes, take it too a fab shop. I bet they could do it for $20 and at least that way the hole would be perfect.
 
You can pick up a hole saw set from harbor freight for $10. You can get through 2 or 3 holes if you go slow and use cutting oil before you burn it up.
 
Unknown-One said:
Considering 4 5/8 Inch isn't a very easy size to find, I would go with a 5 Inch hole saw. Home Depot has one for $27.97
Click to expand...

Plus the arbor for an additional $13.00.

The correct size is 4 1/2" btw.
 
haha, I actually recently cut a 120mm hole in the side of my Antec sx1040... but I used a dremal and some cutoff discs.

I dont think it turned out too bad for my first attempt, it was a little rough but it cut it pretty fast. I could have spent some more time rounding the hole out but it was more of a performance mod than a cosmetic so I wanted it done asap...
 
eBay is your friend on hole saws.

I bought a complete set (equivalent sizes for 80/92/120mm fan versions. Remember when buying a hole saw, get it just a little bit smaller, otherwise your hole will be wide enough to show the fan frame.
 
be careful when buying cheap tools, companies like http://www.homier.com/ have crap availible that will literally fall apart during its first use. (though they've got some damn fine deals as well)
 
Yep... nothing more dangerous than crappy power tool attachments.
Good point to keep in mind!

If it sounds to good to be true, it probably is!
 
Re: hole size for 120mm fan

Just used a digital micrometer to measure 120mm fans of three different brands. Hole size in fan frame is 4.590" .... just a hair under 4-5/8" (4.625).
 
oops, yeah you need a 4 1.2" (since I don't think they make a 4 5/8" tool). I forgot that the frame is part of the 120mm measurement.
 
when i did it, instead of spending money on different size hole saws I just used a dremmel with diamond bit cutting wheels. They would burn out pretty fast but the wheels are cheap. All you have to do is put the fan on trace the hole and cut with the dremmel. then you can sand down the rough edges.

this worked like a charm. not to mention a dremmel is damn handy to have around.
 
Agreed - Dremel or similar tool is the best bet. Holesaws are for those with less experience around a toolbox.

BTW ... those diamond coated disks are for cutting tile etc ...... much too expensive for any other purpose IMO. Especially when you can get a pack of 25 fiberglass reinforced cutting disks for $7 ~ {clicky}
 
Susquehannock said:
Agreed - Dremel or similar tool is the best bet. Holesaws are for those with less experience around a toolbox.

Whatever people. I can use a Bi-Metal holesaw for a 120mm hole and dremel it clean in 1/5 the time it takes anyone to use a dremel and it be PERFECTLY round. Which there would look better than anyone who used a dremel. Don't be so quick to insinuate people are inexperienced because they don't use the same tools. I've said from the beginning; if you don't use jigsaws to cut windows or holesaws to cut holes then you're insane. I would never use a dremel for cutting out a window or a fan hole. Ever. Takes way too long and way too much risk of slipping. Maybe you could use a little more experience around a tool box.
Click to expand...
 
Levell0rd said:
Susquehannock said:
Agreed - Dremel or similar tool is the best bet. Holesaws are for those with less experience around a toolbox.

Whatever people. I can use a Bi-Metal holesaw for a 120mm hole and dremel it clean in 1/5 the time it takes anyone to use a dremel and it be PERFECTLY round. Which there would look better than anyone who used a dremel. Don't be so quick to insinuate people are inexperienced because they don't use the same tools. I've said from the beginning; if you don't use jigsaws to cut windows or holesaws to cut holes then you're insane. I would never use a dremel for cutting out a window or a fan hole. Ever. Takes way too long and way too much risk of slipping. Maybe you could use a little more experience around a tool box.
Click to expand...

Right tool for the right job. Something my dad would yell at me when I couldn't find a hammer and tried a big ass wrench to do it's job, or a flat tip driver for a phliips head screw. :)
Click to expand...
 
ryan_975 said:
Right tool for the right job. Something my dad would yell at me when I couldn't find a hammer and tried a big ass wrench to do it's job, or a flat tip driver for a phliips head screw. :)
Click to expand...


Those were the days man..... :D
 
You know, a jigsaw can make some pretty good holes if you A) have the right blade, B) go slow, and C) follow a pattern.

Also, jigsaw blades are cheap compared to hole saws ;)
 
Unknown-One said:
You know, a jigsaw can make some pretty good holes if you A) have the right blade, B) go slow, and C) follow a pattern.

Also, jigsaw blades are cheap compared to hole saws ;)
Click to expand...


Darn skippy man. $28 a piece?? :eek:
 
Yes ... right tool for the job. Duh!! :p

Was merely saying a Dremel or similar tool is far more versitile. Although they do require more experience. Which is what I was trying to say above.

Basically, the old multi-tasker vs. uni-tasker argument. Buy a $30 holesaw that can do one job and one job only, or buy a tool that can do a wide range of jobs, including the fan hole.

Far as job speeds goes. Not everyone uses a Dremel. You might be surprised how quickly I can cut a 120mm fan hole with a pneumatic die grinder, w/reinforced disks & carbide bits.
 
Takes me a minute to mark off and measure the 5 holes, another minute to pilot and funnel all five. Then 45 seconds to knock out the middle, maybe 2-3 minutes to dremel if at all and I'm all done. You?
 
I’ve fabricated a pattern template out of plexi to mark 80mm, 92mm, and 120mm fan holes.

So it takes me less than a min to mark off the pattern. 5-15 min to cut the hole using the appropriate holesaw (go especially SLOW on aluminum!) Then its another 2-5 min to smooth the edges with a rounded file + folded sand paper. I have to re-sharpen my bi-metal holesaw every 5-7 uses (depending on material.)

For me, using a dremel to get the same pro look would take 30-40 minutes.

Not to mention I’ve burned up more than my share of Dremel’s doing things like that! :p
 
Oh, and it also helps to use a drill press with the worksheet/metal clamped down appropriately against a wood or plexi block.

:D
 
I use a tungsten carbide dremel cutting bit to cut the holes for fans.... it works great and doesn't take long. after cutting I run a sanding bit around it to smooth the edges. this works perfect and my cutting bit hasn't dulled yet so.....
 
Levell0rd said:
Takes me a minute to mark off and measure the 5 holes, another minute to pilot and funnel all five. Then 45 seconds to knock out the middle, maybe 2-3 minutes to dremel if at all and I'm all done. You?
Click to expand...
What is this now, a speed contest? Everyone has their level of experience, and favorite tools.
The question is how you feel about the job when it's done.

workbench -
- http://img158.imageshack.us/img158/1700/bench1aba7.jpg

round holes in mobo tray = hole saws, larger = die grinder -
http://img340.imageshack.us/img340/7191/backnew7sy.jpg

side window -
- http://img74.imageshack.us/img74/3508/spin1ex7.jpg
- http://img73.imageshack.us/img73/4427/spin26kh.jpg
roughly 15 minutes cut time after layout. Try that with a hole saw ... j/k :D
 
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