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DIY: Blowhole |
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Intro
Extra fans are have long been a mainstay of computer modding and overclocking. This article shows newcomers how to install a blowhole, a simple mod for anyone to cut their modding teeth on. The principles here apply equally to other airflow improvements, such as side panel inlets. Get out of premod hell with the aid of a minimal toolkit, and have your fans exactly where you want them!
Marking out
Use a layer of duct tape to project the top of the case, then a layer of masking tape on top of that to mark on. Where space is tight, hold the fan on the inside on the position you want, then use something the same size (like an old filter) on the outside to make sure things line up. Otherwise, just put the fan on the outside & mark the screw holes. Marking a line down the centre of the case, and on the fan itself beforehand is also a good idea. I used the fan grill as a template to get the cutting line for the blowhole itself, after lining the screw holes up with those I'd already marked on the case.
You'll see the PSU & a CDRW are still in place in the photo, I've left them in to help me get the best position for the hole. These will be removed before I do any cutting. Removing your components from your case for a mod like this is NOT optional: the risk of vibration damage and /or short circuits from metal fragments is just too great. If you've never stripped down a PC before, do yourself a favour and make copious notes and sketches (especially of the case switches / LED headers on the motherboard), even take photos or Polaroids. If you use a digital camera, make sure you download & print out the pics _before_ you take your rig apart.
Editor's Comment:: I have created a template set for you to use for fan hole cutting and fan screw holes. Simply click the template thumbnail to open the full template image and print it or right click the link and select "Save Target As" to save the image to your hard drive for later use. -- GlitterKill
Cutting / Drilling
I used an automatic centrepunch, 5mm and 10mm bits in an electric drill, a jigsaw to cut the hole (tricky on a hole this size), and a grinding wheel in a Dremel to tidy up afterwards. This doesn't mean that you have to go out and buy the same kit; you can do a mod like this with a far more basic toolkit. The minimum spec is something like a nail to punch the drilling points & a brick to hit it with, a round needle file or rat tail file, a drill bit of a size to make clearance holes for the fan screws, another bit big enough to get your file through, and a hand drill to drive the bits. In that case, you'd need to chain drill, that is, punch then drill a series of holes inside your cut line, then use the file to join the holes. If you're new to modding, I recommend that you practice on something other than your case first. An old case is ideal, but also consider any sheet metal of a similar thickness: car doors, washing machine & fridge cases are ideal … although not if you plan to use them again afterwards! Cleaning up is a matter of removing any remaining tape, vacuuming the swarf & filings out of all the crevices, and then giving it a wipe over with a damp cloth.
Fitting Up
This is the quickest, easiest and most satisfying bit. Check the direction of flow of your fan (it will either be marked, or in general, air flows from the better looking side to the ugly side), then hold your fan in place on the inside, the grill on the outside, and screw together. You may well end up needing three hands for this! I used half inch #12 self-tapping screws, as they go straight into the fan without any need to mess about with nuts & spanners. I used standard edging strip, as otherwise the edge of the hole would have been exposed. With modern fan grille designs it may not be necessary, and may even get in the way. If you end up not using it, consider painting the cut edge to match your case: details count.
As this was a 3-pin fan, wiring in consisted of plugging it in to a spare header on the motherboard. Always check the power rating of the fan, and if it's more than 2 watts, check your manual to see if your header can provide enough power without burning out. Other wiring options are dependant on you: if the fan has a 4-pin Molex / Berg connector, plug it into your PSU, you might want to put a simple switch in the circuit too, or build / use a baybus or rheobus, and so on.
Conclusion
I'm the first to admit that my finished mod is purely functional, but the principles here are the same for bigger, better and/or illuminated fans, and better grilles. If you've read this article and thought "I can do better than that", and then go and do it, I'll consider that a great result.
The actual mod took me 40 minutes, including the marking up and fitting. Taking the components out, then putting them back in afterwards took another 4 hours. Remember, the important thing is to do it right, not to do it fast.
A final pic: this is the same hole with a Mitron "Shuriken" grill and blue Halo CC fan.
