Add an exhaust or intake fan – Case Mod

Many articles and studies will tell that too many case fans is a bad thing. The ideal air flow setup is one intake and two exhaust (one being the PSU). But there are times that you will need to add an extra case fan.

You will need a power drill and a hole saw. For a 120mm fan you will need a 4-3/8 inch or 4-1/2 saw depending on your mood. For an 80mm fan you will need a 3-1/8 inch saw or a 3 inch depending how you like it. For a 92mm you will want a 3-1/2 inch saw. You may also want a fan grill to keep loose wires and such from hurting the fan.  I used a 2-1/8 inch saw on this project.

If you are planning on doing this on a thin case side panel, I suggest doing this on a work bench to prevent bending.

102_0147This is my main router. The top does not come off so I am forced to cut just like you see in the photo.

102_0148 This is the tool that I will be using.

102_0149 Start to drill where you need the hole to go. Make sure you have picked a good place for your extra fan. Keep in mind of things behind the fan.

102_0150 102_0151102_0152I will take only a couple of seconds to start the hole. Also, if your hole saw starts to heat up take a break. You be able to get a good clean cut if you keep your drill level.

102_0153 As you can see I have to option to sand down the side. The hole saw cut a nice clean hole for me, no rough or jagged edges.

102_0154 102_0156Next I drilled holes for the screws. I only needed to put in two.

And that’s it. It took me 10 minutes to put in the fan. Don’t forget to vacuum to shavings up. If you wondering where to get the tools check out http://www.crazypc.com/.

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