I am up the river without a paddle...ARRRGH!!! WHO AM I KIDDING? I AM TOTALLY SCREWED! What do you guys think I should use to cut my sheet metal!?!? I can't find anything to cut it with and my alst dremel bit used for that broke!!!!

ARRRGHH!!!!!
Mr Black Cat

If it's thin enough, you may be able to use tin snips, otherwise you may have to get either a real grinder, or a dremel bit made for tougher metal.

Or go oldskool on it...... hacksaw!

Snipsnipsnip! I thought you were getting a vasectomy!

jigsaw with the right blade.

bah, hammer and a nail. takes a lil work. But it makes a nice rough cut.

Try a Nibbler. Takes a while, but it works pretty well. I used one for my first window mod and it came out perfect. Just outline the area you want cut and then "nibble" away......

Ha~ha chavalcito! My lord, so immature. Had you moved your eyes yet another 1/8",
You would've seen that i was talking about sheet metal. Nibbler, eh? I saw that once or twice, real nice, I'll say. Hammer with a nail? haven't heard that before.....creative....
My jigsaw is shot.....but i found a metal-cutting rotary saw blade.......works pretty nice.
What kind of dremel attachment? could you give the specifics? like name and stuff?
Also, sorry if I was rude at all here....My allergies are really bad today.

I am sleepy and have allergies:
Mr Black Cat

One of these with as many tpi on a bimetal saw as you can get.



I just got done building two separate gold dredge sluiceboxes from scratch with 0.063" aluminum...so I KNOW this'll work for you!

What's the price and were do I get one?

Asking simplistic questions:
Mr Black Cat

If you just need to cut fan holes, get a holesaw(attached to and drill) and cut perfect circles.

Uhhh, I doubt hole saws cut squares...........not to be sarccastic.

I want some pie:
Mr Black Cat

Sorry, did not know what shape you were talking about.

My bad, I should've mentioned it in the original post. By the way, do you know what the best size holesaw bit that is good for 120mm holes?

Good thing you said fan holes:
Mr Black Cat

120mm = 4.7244 inches, so look for 4 3/4"

I disagree. I suggest going slightly smaller than 120mm, instead of slightly larger. I don't know what sizes hole saws come in though. I know a few people have suggested 114mm diameter in other threads.

I have only seen them sized in .25" increments, so going smaller to 4.5" might block some air flow.

Yeah, it might block airflow if you leave it at 114mm (or whatever). But, if you file the edges to make it smoother, it might decrease the size a bit. And I would like to point out that the 80/92/120 measure to the outside of the fan, not the blades. For example, the blades on my 80mm fan here are only 76-77mm. So, only a tiny amount of air would be blocked, if any. For reference: 4.5" = 114.3mm, 4.75" = 120.65mm. You would see the edge of hole on the outside of the fan with a 4.75" diameter cut.

EDIT: Just to clarify, most fans are 80x80mm (or whatever size) squares

Good point, what I did on a previous mod was to put some rubber edge around the cut hole to fill in a bit, it worked good.

That's a good idea. If you're going to put rubber around the edge (I think it's a cool idea), then go with 4.75"

I,m with everyone suggesting a jigsaw with a blade having a ton of theet per inch, they're expensive to buy but if you have balls and dont have one you'll definitely need one again somewhere in your near future so might as well buy it now

We never have enough tools.

Sounds like a nice sig to me loll