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Thread: Guide: Installing GPU Cooling Fan in Side Panel

  1. #1
    Modding Master

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    Default Guide: Installing GPU Cooling Fan in Side Panel

    One of our customer sent us their Cooler Master Cosmos case to install a 120mm cooling fan and grill in their access side panel. Here are the steps we took in performing this case mod with a Greenlee Knockout Punch, but you can use this guide with 4.5" Hole Saw attachment on your Power drill or Drill press.

    List of Tools We
    Power drill or Drill Press
    Greenlee Knockout Punch with 120mm cutting blade, but you can use your own 4.5" Hole saw Attachment
    Measuring Square or Ruler
    Pencil or Pen
    Painter's Masking Tape
    Center hand punch
    X-acto Knife
    3/16" drill bit for fan screw mounting holes.
    Mouse Sander for removing adhesive residue from the sound insulation foam.
    Phillips Screwdriver
    "SEM brand Self Etching" Primer
    Plastikote's Silver "Engine Enamel" automotive aerosol paint.
    4x 8/32 Thread x 5/8" Length Socket Machine Screws
    1x 120mm Wire Fan Guard
    1x Black 120mm Round Hole fan grill
    4x #10 x 5/8 self tapping fan screws



    Our customer marked off the 120mm GPU Cooling fan hole location for us, with low tack masking tape.




    1x 120mm Wire Fan Guard



    Using a 12" measuring Square and 120mm Wire Fan Guard to mark the fan hole location.



    Using hand center punch to mark the center of the grill location. This is for the 1" diameter Hole Saw attachment pilot drill bit.



    At this point, you can use a 4.5" Hole Saw Attachment on a Power Drill or Drill Press to make the 120mm fan hole.



    The 1" opening allows us to insert the shaft of the Greenlee Knockout Punch blade.



    Using X-acto Knife to cut square shape in sound insulation foam on backside of the panel.





    I used a Black & Decker Mouse Sander to remove the adhesive residue left by the insulation foam.

    To save time, we use a Greenlee Knock out Punch at Mnpctech.com. Greenlee part # 730EBB-120. Last time I inquired, they were around $450 in the states + Large 3/4" socket wrench, and 2" socket. I wouldn't use anything less than 19" long socket wrench. Estimated purchase price of $550 new.









    Crank and tighten the socket wrench to cut through the panel.









    Using 3/16" drill bit to make fan screw mounting holes.



    The advantage of using a Greenlee knockout punch is that the cut is clean! No need to clean up jagged edges.



    I painted this Black http://www.mnpctech.com/120mm_Custom_FanGrill.html
    120mm Round Hole fan grill with Plastikote's Silver "Engine Enamel" automotive aerosol paint.







    4x 8/32 Thread x 5/8" Length Socket Machine Screws





    The 120mm cooling fan and grill installation looks clean and professional!
    Click Image To Visit My Case Mod Store


  2. #2
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    Default

    This Cosmos grained aluminum panel look so nice. It served as a great canvas to compare how our machined aluminum 120mm grills look.

    Heres how the panel looks with 120mm "Turbo" machined aluminum fan grill



    Click Image To Visit My Case Mod Store


  3. #3
    OC Jedi Padawan

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    CPU: AMD Phenom II X6 1055T@4GHz
    M/B: ASUS Crosshair V Formula
    RAM: 4 Gigs Mushkin 1600MHz
    GPU: VisionTek AMD Radeon 6970
    • smduff's Full Spec's
      • Case:
      • Danger Den Tower 21 Black Series
      • PSU:
      • Sentey GOLD 1000W
      • Cooling:
      • Custom Water- EK Supreme HF EK X360 Rad DD 5970 Block MCP655 6X Ultra Kaze 3000rpm 133.4cfm
      • Monitor:
      • LG Flatron 19"
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      • Windows 7 Ultimate 64bit
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    Default

    Now that looks much better, way nicer cover IMO.

  4. #4
    Modding Master

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    Default

    How about this one? a bit overkill...hehe

    Panel with 120mm "Nautilus" machined aluminum fan grill



    Click Image To Visit My Case Mod Store


  5. #5
    OC Jedi Padawan

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    smduff is offline

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    CPU: AMD Phenom II X6 1055T@4GHz
    M/B: ASUS Crosshair V Formula
    RAM: 4 Gigs Mushkin 1600MHz
    GPU: VisionTek AMD Radeon 6970
    • smduff's Full Spec's
      • Case:
      • Danger Den Tower 21 Black Series
      • PSU:
      • Sentey GOLD 1000W
      • Cooling:
      • Custom Water- EK Supreme HF EK X360 Rad DD 5970 Block MCP655 6X Ultra Kaze 3000rpm 133.4cfm
      • Monitor:
      • LG Flatron 19"
      • OS:
      • Windows 7 Ultimate 64bit
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    Default

    Looks good but a little to bulky for the side panel, unless the front had the same ones IMO.

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