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Old 01-29-2010, 01:27 PM's Avatar is offline
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Join Date: Nov 2009
Posts: 469
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I'm removing the factory perforated grill to help improve airflow. This mod will also cut down on airflow noise from your cooling fans.

To avoid creating scratches in the factory finish, apply masking tape over the area you're going to be cutting.

The Obsidian uses "doomed" pop rivets, which doesn't allow the grill to sit flush. I will swap these out to the more flush "countersunk" pop rivets.

Use 1/8" size drill bit to remove the factory pop-rivet

Pop-rivet Tool (Gun)

Tracing the inside diameter of the grill opening.

Using the first 140mm fan grill design, to mark off the location for the hole.

Using Dremel 1.5" cutting wheel to make initial cut into the chassis

Using Jigsaw with 18 TPI metal cutting blade

The case panel lip was removed with the Dremel to fit around the grill.

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