Originally posted by ï¿½ArchOAngelï¿½
not true, the more pressure you apply, to an angle will make the cleanest cut although putting tape around the cut area wont prevent or make much of a difference in the tearing/scratching. the tools youll be using will be quite dangerous and the slightest slip will make a scratch tape or not. and tape only works for acrylic products and similar types and glass product. if i knew what case you had and the finish gloss on it i could ask my dad and he could give you the best tip for cutting a hole in the top. he did mine. we made a octagon shaped hole and then just drilled 4 holes for the screws to go in the fan and used washers under each to give it alittle lift so if it ever got out of its centrifigul rotation wont hit the case.
Well, I was a car audio installer for 9 years, and in my current job I assemble/modify/setup and deliver power wheelchairs and scooters, both jobs call on the use of a hole saw regularly for various reasons. Applying pressure when using a hole saw won't do anything but make it cut through the material faster, and cutting through sheet metal w/a hole saw tilted at an angle isn't recommended for a few reasons. Main one being that there is normally a drill bit at the center of the holesaw so if you get the bit throught the metal and then tilt the drill, you risk bending/tweaking the sheet metal. Also, once you get about halfway though it, you're gonna have one side pushing down on the metal while the other side is pulling it up, again, risking bending/tweaking the thin metal.
Using masking tape will absolutely help protect the immediate area from getting scratched or marred due to the metal shavings and adds a layer of protection against light impacts from screws, bits, etc, this is especially important if you have a case with a glossy finish. Not only does it only take seconds to apply/remove, but if it can help protect your item, why not do it?
Also, if you had cut the correct shape/size hole for your fans, you wouldn't have needed to add any washers like you did.