Bluefront wrote:
Depending on the space you have, you could just cut out the grill, and mount any 80mm fan external to the psu case, using the original four fan holes.
You read my mind
The first PSU I ever modded is the AOpen PSU on the right. That was almost two years ago and it was an imitation of two of your mods. The one where you put the fan partially on the outside and the one where you move the PSU forward in the case. It powered and cooled my Prescott 3GHz machine. It was a lot quieter than unmodded, but not quiet enough.
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This is the final plan I came up with. An earlier plan included soldering an extra connector to the fan leads to act as a "Fan Only" connector. But then I realised I could use the 4-pin pass through connector of the Nexus fan for that. One of the reasons to solder connectors to the fan leads and not soldering the leads of the new fan directly the the leads from PSU, was that I wasn't sure the Nexus 80mm fan I was planning to use was powerfull enough to cool this PSU. I it wasn't, then this would allow me to easilly swap in a faster fan or a 92mm fan. Though that last option would require enlarging the hole in the PSU cover, I still wouldn't need to resolder anything.
The first step was cutting the leads to the stock fan and stripping the outer insulation. Then I got interrupted and shelved the project for over two weeks.
Here are the tools and materials I gathered before the project. I forgot to get the zip-ties and the fan for this foto. In the end I used other heatshrink than the green one pictered too.
With a jewelers screwdriver I pushed on the middle contact of the female connector. This allowed me to slip the red wire out. That (two wired) end of the cable will be used to report the PSU fan's speed to the motherboard.
I cut the wires. Then I stripped and tinned the ends. The right picture clearly shows the absence of any skill in soldering.
Next I soldered the appropriate ends together and hid the joints under some heatshrink.
Everything neatly zip-tied. Ready for closing the PSU.
Here the PSU cover is put back on. Note the absense of the fan grille. Tin snips are really wonderful tools.
Lastly a fan is mounted on the PSU. The rubber fanmounts allow me to just push the fan on the PSU from the outside. With a little force the fan can be removed from the outside again. The rubber fanmounts survive this. At least, if you don't do it too often. If I had used screws, then it would have been necessary to open the PSU to switch the fan.
To check if the 80mm Nexus fan was powerfull enough, I measured temps at four places before and after the mod. The system used for this is the same one as in the first post in this thread. Since the PSU is not not installed in a case the intake temps are the room ambient temps. The temps in the column "Wires" are measured at the small exhaust vent next to the wire bundel leaving the PSU. The column "Roof" contains measurements taken at the row of small vents at the side of the PSU near its top. Lastly I measured the temps at the middle of the "Rear" exhaust.
Code:
Temps (°C)
Load Intake Wires Roof Rear
Unmodded:
Idle (51W) 23 30 31 28
CPUburn (79W) 23 31 29 28
Modded (Nexus 80mm):
Idle (51W,6.05V,710RPM) 24 30 36 30
CPUburn (78W,6.27V,745RPM) 23 31 39 31
The PSU startup fan voltage is 3.60V. The 80mm Nexus fan doesn't start at this voltage. After about two minutes (while the system is folding, room temp 18°C) the voltage rises to 4.95V at which point the Nexus fan starts. After about one and a half hour (still folding) the room temp was 22°C and the fan was fed 6.21V. (No it wasn't the PSU nor the rest of the computer that caused the room temp to rise that much. I just turned on the central heating.)