Getting Started. Again.

If you're going to cut a hole through a computer case, the first thing you need to do is remove everything. Absolutely everything. And if you really can't remove something, make sure it is covered in masking tape. A single speck of metal in your case and it can be curtains for your entire system.

Everybody Out!

You can see on this picture the shoddy job I made of removing the fan grille with tinsnips on the previous mod. I just really couldn't be bothered taking everything apart again at the time, but I'll need to tidy this up now as it'll still be visible once we're done. You can also see that there's been a bit of muck building up.

Untidy Tinsnip Work

I made a template of the radiator out of a piece of card to check that I wasn't going to remove anything too critical and to get the position just right. The main issue is to leave room for the optical drive caddy to move in and out, although you also need to be careful that you don't block the threaded hole that the side panel attaches to, or position your bolt holes anywhere foolish. Mine ended up just touching the back case seam, which made drilling a little trickier, but it was the best overall position. I was also careful not to take out the antenna mounting point or too much of the rear drive caddy mounts - just in case.

After carefully marking up in pencil and putting masking tape on all of the door holes, cable ends and any gaps near the speaker and power button, I got out the rotary tool. Actually, I first had a good go at it with a 102mm hole saw, but my hole saws are rubbish. It left me with a nice circle to follow though.

The New Hole

It took about 12 cutting discs to cut the entire hole, as the metalwork on the PowerMac G4 is rather thicker and denser than on most other machines I've come across. No wonder it weighs so much. This also covered the whole of the inside in a mixture of metal filings and disintegrated cutting discs, so the masking tape is very useful. Lastly the bolt holes were drilled through using increasing sizes of metal drill bits. This was required particularly on the seam on the rear of the machine, where things were a little trickier.

I popped the antenna back in place and was very chuffed to see that it was well out of harms way. The top caddy mounting point was untouched and part of a lower one was still partially present, so it still hold a caddy if every required to do so again. The next thing to do was tidy up the messy ex-fan grille, then try attaching the radiator to the side.

Test Fitting >>