PART 4
PREPPING FOR THE 80 MM SIDE
INTAKE FANS

Here's where the serious sheet metal work starts... making openings in the left side panel for the four Sunon 80 mm intake fans.

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This gets a bit tricky on some cases.  You can see the measurements on the panel.  These are distances from the edges of the panel, and the fans must all be within this space to keep from interfering with the chassis.  I was a bit off, as the bottom measurement is closer to 3/4", so 1" is safe, but the 7-3/4" measurement should be closer to 7-1/2"... gotta be careful or the fans will hit the 3.5" drive cage!
 
I decided to move the fans back a bit away from the front of the case.  I started by laying out the filter covers (they are bigger than the fans) and shooting diagonals through the mounting holes.  If all of your diagonals are true and your spacing on the bottom and front edge are true, your fans will be straight and square, with equal spacing between them.  Due to the limited clearance inside of the case, I had to keep the filters about 1/8" apart... enough to reach in and pop the covers off for cleaning.
Place the fans on the panel with the diagonal lines visible in the mounting holes...
... and trace the inside diameter of the fan.  80 mm fans are just a touch over 3-1/2" diameter.
All of the openings marked out...
...and starter holes drilled.
I tried using a hole saw and smoked my drill.  Time for the backup tool.
Don't forget to deburr, inside and out.
Put the filter bases in place.  Now is the time to make any final adjustments.  I like using filters because the holes don't show as they do with wire grilles, and you can be a LITTLE off without exposing the hole.  Also, I have cats.  All air going into the case MUST be filtered (and cleaned weekly).
Once the mounts are lined up, mark the corner holes...
...and drill. 
I'm not worried about the marks on the panel because the case will be stripped and repainted.

 
 
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