Case modders & Structural Engineers - Need your advice please

Space Monkey · 31 May 2019 at 15:32

Hi all,

I've recently bought 2 x 480mm radiators for my water cooled PC, but as the rads are multiports the top 2 ports are fouling the bracket that holds the rads (pics below).

For now whilst trying to find the best option for fitting I've used 2 slightly longer screws at the front nearest the red plugs as shown in the photos to hold the rad to the bracket, but as you can see it's pulling the bracket and putting pressure on the whole thing (and that's without putting fans, fittings, fluid and tubing on it!)

So my query is this, can I safely cut out a small section in the bracket around the red plugs to allow the rads to sit correctly? Will this cause the bracket to become weak, bend, cause issues or problems later on?

alexakasloth · 31 May 2019 at 16:22

The fold in the sheet gives it rigidity, I wouldn't cut that away with the amount of force that is being placed on it

Space Monkey · 31 May 2019 at 23:49

alexakasloth said:
The fold in the sheet gives it rigidity, I wouldn't cut that away with the amount of force that is being placed on it

That's what I feared

Thanks for the confirmation.

Danny75 · 1 Jun 2019 at 07:18

Here's a thought - create a new fold after cutting the necessary area out. Rather than soldering, maybe add an L-shape bracket with screws or rivets to act as a fold there, for support.

Would something like that work?

ANDARIAL · 1 Jun 2019 at 09:32

My 2p worth
Just cut out the 2 small notches
Its not like it is needing to support a huge weight is it?and unless you go lugging it around to lan partys(unlikely looking at the size of that case)
I would not worry or do as Danny suggested make a small bracket/strap

Jokester · 1 Jun 2019 at 09:35

Yes, my opinion is that it'll be fine cutting out the notches as well. It looks a good 2mm thick metal?

It'll be way over engineered for any loads.

Goose · 1 Jun 2019 at 16:55

Can you not just use a gasket between the radiator and the bracket with longer screws?

Space Monkey · 1 Jun 2019 at 17:25

Would something like this be best to cut a hole into the metal?

Quartz · 1 Jun 2019 at 17:41

Space Monkey said:
Would something like this be best to cut a hole into the metal?

Use a hacksaw.

Danny75 · 1 Jun 2019 at 17:43

You can also get a set of diamond coated hole saw drill bits, for less than a tenner, with diameters of 8mm, 10mm, 12mm etc. Cut from the side that doesn't have the fold and create a nice semi-circle.

EssexBoy · 1 Jun 2019 at 18:02

Easy work with a dremel.

Jokester · 1 Jun 2019 at 18:19

EssexBoy said:
Easy work with a dremel.

*thumbs up*

Space Monkey · 1 Jun 2019 at 18:22

Don't have a Dremel sadly and it's too much dosh for a small single job

@Danny75 those diamond cutters don't seem to do metal, unless I'm missing something?

I'm looking at metal hole cutters or a hacksaw so far

EssexBoy · 1 Jun 2019 at 18:26

Drilling so close to the edge will be hard work and messy.

A coping saw and files would be the best way without powered tools.

Danny75 · 1 Jun 2019 at 18:44

Space Monkey said:
Don't have a Dremel sadly and it's too much dosh for a small single job

@Danny75 those diamond cutters don't seem to do metal, unless I'm missing something?

I'm looking at metal hole cutters or a hacksaw so far

My bad. I'd been looking at ones for wood recently for a DIY job. There are different ones for metal though. But if you don't have a drill handy then no go.

Space Monkey · 1 Jun 2019 at 18:45

A drill I do have thankfully, thinking of drilling from underneath and creating a hole/semi circle?

Danny75 · 1 Jun 2019 at 18:46

Space Monkey said:
A drill I do have thankfully, thinking of drilling from underneath and creating a hole/semi circle?

Yeah. Should be a fairly easy job compared to sawing through 6mm steel like this chap:

https://www.youtube.com/watch?v=aj12WdVhOCc

Danny75 · 1 Jun 2019 at 19:03

Taking a look at this as an example (search for a better-known brand if possible):

Hole Saw Cutter MASO 25mm HSS Hole Saw Tooth 6542 High Speed Steel Application for Steel, Metal, Aluminum,Boards

And choose a slightly larger diameter than required due to the pilot bit in the centre having to go into the metal as well, so it'll create a bit more than a semi-circle.

Donnie Fisher · 2 Jun 2019 at 23:36

Is it just to expose the red caps of the radiator ?

If so, I would use a set of round / curved hand files. Would have that notched out in minutes, and very easy to control so that you dont slip or go mad with a power tool.

The metal fold lip on the inner edge your cutting away will provide some form of rigidity in that area around the hole itself... but the rigidity it provides pretty much ends at the edge of that cut out. The rest of the forces are held by the lip around the outer edge of the bracket. Its that outer edge area where it tapers to the frame which is holding the whole weight of the bracket (and whats attached to it). As you're not cutting that area ... then it should hold fine.

Also, the radiator itself has structural integrity which when screwed to the bracket adds to the overall structural integrity of the setup too.

So go ahead and cut it in my opinion.

Space Monkey · 2 Jun 2019 at 23:46

Donnie Fisher said:
Is it just to expose the red caps of the radiator ?

If so, I would use a set of round / curved hand files. Would have that notched out in minutes, and very easy to control so that you dont slip or go mad with a power tool.

The metal fold lip on the inner edge your cutting away will provide some form of rigidity in that area around the hole itself... but the rigidity it provides pretty much ends at the edge of that cut out. The rest of the forces are held by the lip around the outer edge of the bracket. Its that outer edge area where it tapers to the frame which is holding the whole weight of the bracket (and whats attached to it). As you're not cutting that area ... then it should hold fine.

Also, the radiator itself has structural integrity which when screwed to the bracket adds to the overall structural integrity of the setup too.

So go ahead and cut it in my opinion.

Yeah it's just to allow the red caps to come through so that the radiator sits flush in the bracket.

Thanks, sounds like it might be a plan

Do you mean the half round files or totally round ones?

Anything in particular I should be looking for when buying a set?