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To get the big 120mm side exhaust in this time I am going to have to cut the mobo tray. Again, used the fan as a template and drilled a starter hole for the jigsaw using a stepdrill.

Template for mobo tray


Then using the hole in the mobo tray, I marked the cover to show the boundries of where the fan can go. Again, used the fan to drill the mounting holes and find my center.

Another template


It doesn't really show in the pic but this is a BIG hole saw!!!

120mm hole


A trial fit shows me the fan body will be slightly touching the mobo tray. This will probably cause vibrations and that is not a good thing. So..... make the hole in the mobo tray bigger!

Need bigger hole!

The fan now fit fine with good clearance. As before, I used rubber faucet washers between the fan and the housing.  
 
 
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