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The grilles are slightly raised. This makes the job easier,
as it provides a nice "trail" to follow, and the angled edge makes it easier
to cut a round hole with a FLAT Dremel disc. Normally, for a 120
mm opening, I would use a jigsaw, or cut a square opening with angled corners
like I did for the front fan opening.
SAFETY GLASSES!!!!!
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Even with the angle, it's still careful going. Make gentle
cuts and do not penetrate the surface any more than needed. It will
get easier as the disc wears down, as the smaller diameter is more "friendly"
to making round holes. Expect to go through 2 discs per fan opening.
I used a total of 14 discs on this project so far.
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You are still left with a very ratty edge...
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...A Dremel makes easy cleanup, or a large half-round file works
just as well.
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Yes, I skipped ahead... this case WAS unpainted in the last photo.
The mounting holes are shown here drilled out to 3/8" to accept grommets.
This case is going to be loud, no doubt about it, but I'd like to do what
I can to keep it tolerable.
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And here the grommets are installed.
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The grilles are mounted with 6-32 screws...
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I screwed up and bought screws that were only 1-1/2" long, so I
did not have enough length to add the flat washer, lockwasher, and jam
nut that I wanted to use. No problem, a SMALL drop of super glue
will keep the nut in place. Look carefully and you will see a rubber
washer between the fan and grille. Combined with the grommet, this
completely isolates the fan.
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DONE!
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