Project Sinister: Something Sinister This Way Comes - A Drill!
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I took a piece of spare case panel I had left over from a previous mod and set about cutting the shape I needed for my fans. Once the panel was cut out, I took it over to my drill press and, with my 3 inch hole saw, set about cutting holes in it for the fans. Whenever you use a hole saw, hold the material you are cutting with your handy clamps. Hole saws have a habit of biting into the metal and causing the material to “kick” in your hands. More than a few times, the sharpened edges of this piece of sheet metal “kicked” and snagged my shirt. That shirt could easily have been my skin. Whenever you’re going to cut something with a hole saw, you’re better off using it in a drill press or with a corded drill. A cordless drill can’t produce the same kind of torque that a drill press or corded drill can and the metal cutting effort often proves too great for cordless models.
Thankfully the piece of spare case panel was polished on the other side. I had polished that with a variety of techniques a while back out of boredom, and the polished finished side would look really good on the chassis (even though I plan to paint it).
Once the plate was made I affixed it to the front of the chassis. Once I was happy with it, I decided I wanted to do the same to the back of the chassis for the exhaust fan. Using the same hole saw, I cut through the imprinted fan cover on the back of the chassis.
Next: Letting the Case Breathe >>
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