In this Dremel projects article will detail how to cut a fan hole in an aluminum sheet.

Safety FirstBefore Starting Any Dremel Projects.

Before you start any dremel projects using any kind of rotary tool or  power tool you must wear safety glasses. You will also need some scotch tape low adhesive tape as it does not leave a sticky residue. For detailing intricate cuts in metal I like to use a variety of hand files including flat, rounded sides and circular.
For me the only rotary tool attachment are the 1 ½” cutting wheel that is reinforced with aluminum oxide so they last longer. In this guide I use the Dremel 4000 with variable speed control, but any rotary tool will work, but stay away from the cordless models, because they simply don’t have enough power.

Dremel Projects Tip

Save partially used cutting discs for intricate detail cuts and small designs.
I like to place an empty cardboard box beneath the piece I am cutting, this way I won’t destroy my work surface and it also collects dust and debris that I create.

• If your are cutting panels apply the scotch tape to protect your panels which protect them as you work, and you can also use it to draw your templates and designs.

• You will notice that the Dremal 4000 has vent holes which they should all have. Grasp the tool so you do not block these holes and always hold the rotary too with two hands.

• When cutting straight lines allow the cutting tool to do the work. Don’t force it! If you force it you will prematurely wear out the cutting wheels, which is a waste.

• One of the most popular questions for dremel projects is how to make a circle or fan hole using the Dremel. Using a circular template, which can be anything that is the exact size of the hole that you wish to cut.

• Draw around your template directly onto the scotch tape. After you have drawn your required circular hole on the tape hold the Dremal at a 45 degree angle. This way you are using the radius of the cutting wheel to make your incision and your cut is curved, not straight. Keep repeating this technique around the diameter of the hole until the hole is completely cut.

• You now have a circular hole and although it is not perfect at this stage you can now use one f your hand files to smooth off the edges.

That’s it,  your  have now made a cooling fan hole with your Dremal 4000.

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Filed under: Dremel 4000 Rotary Tool Articles

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