Dremel Mayhem Continues!!:

Fresh cut-off wheel! Click to enlarge

No need for clamps here!! Click to enlarge

   Before we proceed to the last hole, you might want to slap on a fresh cut-off wheel to the Dremel. The last piece should have gotten smaller due to the friction on the first two cuts. This will also ensure you have a much better cut on the next hole.

   Unlike a hole saw or jigsaw, you do not need to use some kind of clamps or jigs to hold down your work piece when using the Dremel. This is due to the fact that the Dremel only takes small cuts at a time and the kick-back from the Dremel is very little. Try doing that with a hole saw or a jigsaw! I think you'll lose more than your ego!!!

  Getting back to the cut, this time we'll be cutting a120mm hole and the circumference of the hole is much larger so you can take a larger cut at a time. Start by drilling the screw holes first and then check their alignment with the fan and grill.

   I then proceed to cut the hole out with a fresh cut-off wheel and let it cut about one and a half inches of metal at a time, an inch larger than the 92mm hole. Again, do not apply too much force and just let the wheel slide across the workpiece. Continue to do so until finally the wheel cuts through the work piece.

You can take longer cuts here. Click to enlarge

I love those sparks!! Click to enlarge

About 1/3 left to cut.
Click to enlarge

   Working your way along the markings, you should be able to finish the hole in about 15-20 minutes. Change to the grinding wheel again and shave off all the sharp edges on the hole and you'll get something like this.

20 minutes! Not bad! Click to enlarge

Checking the alignments Click to enlarge

Slap on da fans!!!
Click to enlarge

Final Words:

   There you have it! All done with the help of the good 'ol Dremel! I'm not gonna explain why I chose the fan locations as they are, coz this is just not the place or guide!

   As you can see, the Dremel truly is a Case Mod Freak dream tool! Well, at least to me! The cuts you see here are just some of the example of what the Dremel is capable of. And with all kinds of accessories that is available for the Dremel, its' use is only limited by your imaginations!

   It's lightweight, easy to handle, have a whole range of accessories and is a much safer bet than the intimidating hole saws or jigsaws. If you're a mod freak, or a mod freak wannabe, then the Dremel could make your mods a whole lot easier!!!

   For more information on the Dremel, please visit their website.. (Yucks!! I sound like a TV Commercial!!)