There is now a large variety of 140mm cooling fans on the market. They offer higher airflow while reducing noise and power consumption. Here is a step by step guide to installing a 140mm cooling fan in your side panel. This mod will help cool your video cards and processor. We will be using the Antec Sonata Proto mid tower case.

Tools & Supplies:

1. Power Drill or Drill Press.
2. Masking Tape
3. Block of wood at least 2″ thick.
4. Hand Center Punch
5. Cutting oil or WD40
6. 1/4″ drill bit for cutting fan screw mounting holes
7. Rounded side hand file.
8. 140mm cooling fan template print out
9. C-clamps to hold the panel in place (Optional)
10. 5.5″ size Hole Saw Attachment for installing 140mm fans (140mm = 5.51181″)
11. 1/2″ Hole Saw Arbor
12. 140mm Yate Loon Blue LED Cooling Fan
13. U-channel rubber trim molding.
14. Fan vibration rubber grommets.
15. #10-5/8 Black Cooling Fan Screws.
16. 140mm Wire Guard Fan Grill.

I ordered a MORSE brand 5.5″ size Hole Saw Attachment for installing 140mm fans (140mm = 5.51181″)

MV MORSE AV88 140mm hole saw attachment.

You will need a 1/2″ Hole Saw Arbor in order to use the 140mm hole saw attachment.

Attaching the 1/2″ Arbor.

I’ve attached the hole saw to 18V BOSCH Cordless Drill

You can use either a Power drill or Drill press. I’m using a 12″ Craftsman Bench top Drill Press. Mfr. Model# 21914

The Drill Press offers better precision and stability over using hand held Power Drill.

Applying Masking Tape to the 140mm fan hole location on the access panel.

Place a 2″ thick or larger block of wood beneath the side panel, so you don’t ruin your work surface.

You can download 140mm cooling fan template print out

Taped the 140mm cooling fan template print out for location of the hole.

Using Center Punch to mark center of the hole, which helps pivot the drill bit in the Hole saw Arbor. Also mark the four fan screw mounting holes.

I’m using the Drill press with the 140mm hole saw attachment.

I’m using C-clamps, placed over pieces of plastic to prevent scratches on the panel and hold it in place.

Spray the cutting area with “Cutting Oil” or WD40 before cutting the hole, it reduces heat, so the hole saw blade will cut more efficiently.

The hole is cut, now use a Rounded side hand file to clean up the jagged edge of the hole.

Using 1/4″ size drill bit to make the fan screw mounting holes.

The 140mm cooling fan hole is now ready for installing U-channel rubber trim molding and Fan vibration rubber grommets.

Fan vibration rubber grommets.

I use a Micro Flat head screw driver to install the Fan vibration rubber grommets.

Give the fan hole a professional look by installing U-channel rubber trim molding

The U-channel molding will cover any mistakes or scratches made while cutting the fan hole.

I use #10-5/8 Black cooling fan screws for installing any size cooling fan.

The 140mm cooling fan is installed and looks good!

You can install the cooling fan as Intake or Exhaust, depending our your individual needs. You can use this guide to install the cooling fan as Intake in the floor of your chassis or in top panel of the case as an exhaust.