Next on our task list was to drill the blowhole for the case. The dremel was perfect for cutting the case but for this we needed the heavy-duty power of the drill. The heft, the solidness, the unbridled passion... sorry... getting carried away. Using the drill is a lot of fun. Definitely on the list of "Tools that every guy should own". Measuring is very very important on the plexiglas because you won't get another chance. If you screw up the case, you'll probably see more of the Power Supply Unit than you intended or you make a bad jagged cut which you need to fix or use molding to cover... you screw up where the blowhole is and your fan won't fit in the case. Remember that a fan needs power too so the cabling can be too far away from the power supply. The plexiglas will come with a protective plastic sheeting. Don't remove it until you're finished everything. We reinforced the areas we were going to cut with duct tape. The hole saw comes with an attachment that fits into the drill. This is a large drill bit that the hole saw bit fits around. We first used a smaller drill bit to make a "pilot hole". Basically a starter hole that we could put the bigger hole saw drill bit into without worrying about skating all over the place. It's a bit scary because plexiglas can shatter so you want to take this very easy... nice and slow. The duct tape around the plexiglass front and back helped to lesson the impact of the hole saw bit cutting through.

Pilot hole drilled and ready for the hole saw. Note that blue plastic that the plexiglas comes in helps protect the finish	Whew! It's scary to cut, but look at how nice the hole is.

Once we cut through the plexiglas we got ourselves a perfectly round hole. Absolutely beautiful. The next step was to carefully drill the four holes around the fan where the mounting screws would go. We used the same procedure with duct tape and a small bit. Remember that your drill bit should not betoo small. Too small and the screw going into the mounting will crack the plexiglas.The final thing we needed to do was to cut out the slow where the metal strut in my case but up against the roof of the cover. Basically I needed a slot in the plexiglas. This was cut using the dremel. Once caveat here, use a slower speed setting because plexiglas will melt and begin to coat your cutting wheel. Too much coating and your wheel stops cutting. Once we were done cutting the slot, there was some residual melting plexiglas on the edges which we simply broke off.by hand.

Nifty souvenier. This is what was inside the hole saw bit after we finished cutting	Hard to tell but we had to cut the plexiglas along the thick black line to make room for the metal strut in the case.

How it all looks with the holes and in the case.

Next: Putting it together