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[Modem Mod] 80mm fan on my Cable Modem

post #1 of 8
Thread Starter 
So I was tired of my modem getting a little on the warm side. The outside of the case was pretty warm to the touch, and the heatsink on the chip inside was too hot to touch. So I modded the case, and added a fan on the top...blowing air inside, and venting it out side holes that I drilled out. This idea was inspired by the Actively Cooled Modem/Router Club thread.

The fan is a little noisy sitting on my desk...but once I finish up my mDC, it will be out there and the noise won't matter.
Thomson Cable Modem Photo Log (Click to show)
The modem. You can see the "warranty is void if removed" sticker, as I was able to remove it in one piece...to put it back when I'm done.
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The fan laying on top.
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The inside. The large gray square is a heatsink, with the chip under it. This is what the fan will blow on.
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inside, from another angle.
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Fan has been mounted. Scrap plastic behind it.
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Fan mounted, with the underneath cut out. Cable running through the hole, so it will be out of sight.
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Underneath shot...fan mounted, hole cut out. Did all the cutting with nothing more than a drill bit, bahaha. I also cut 7 holes on each side of the case, for exhaust. The stock holes were tiny, and I figured the air pressure would be too high with this little powerful fan...so I made some of the larger.
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Power leads soldered underneath, on the DC jack.
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The PCB board, showing the fan power wires coming from underneath.
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PCB board placed back in the bottom part of the case, showing wires coming from the side...front view.
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PCB board placed back in the bottom part of the case, showing wires coming from the side...back view.
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Case re-assembled, upside down view of the right side. 7 holes were drilled to allow for better airflow out of the case, since the fan is blowing air into the case.
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Case re-assembled, upside down view of the left side. 7 holes were drilled to allow for better airflow out of the case, since the fan is blowing air into the case.
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Case re-assembled, front view. Done!
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Video of the completed modem, showing it still powers on, fan spins, and lights are working. Obviously it is working right now, or I wouldn't have been able to upload this video. smile.gif
Been running for about 1.5 hours, and is running strong. Very cool to the touch!!! Let me know what you think guys.

EDIT:
I managed to break one of the fins, but I added a new 80mm fan which is quieter, and more powerful. Check it out.


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Let me know what you think!
Edited by tycoonbob - 7/16/12 at 4:39pm
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post #2 of 8
Thread Starter 
So it is a 60mm fan, and I found a 60mm fan grill for $0.87 shipped! Should have it later this week.
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post #3 of 8
its so sleek and seamlessly integrated
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Phobya Xtreme 200mm Radiator XSPC EX120 120mm Radiator Silverstone AP181 Fan Gentle Typhoon AP15 
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Windows 8 Professional x64 HP LP3065c DasKeyboard Ultimate Model S Seasonic X650 
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post #4 of 8
Nice work! Everything should be cool, even modems need care!
thumb.gif
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post #5 of 8
post #6 of 8
Thread Starter 
Quote:
Originally Posted by Skoobs View Post

its so sleek and seamlessly integrated
Thanks. I thought it turned out really well, and only took maybe 2 hours of work. Wasn't that hard at all!
Quote:
Originally Posted by Lt.AldoRaine View Post

Nice work! Everything should be cool, even modems need care!
thumb.gif
Yes they do! I currently have 3 servers, a PC, 2 laptops, 2 switches, a printer, and a other networking equipment in my office, which makes it warm...naturally. This has already helped a ton, and I would assume will make it live longer. Could also potential improve performance when under load too.
Not quite sure what the link is pointing to exactly.
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post #7 of 8
Thread Starter 
Well...to show how unlucky I am...I broke it. The fan, not the modem. I decided that I wanted to feel of the heatsink after it had ran for a few hours, to see what it felt like. Well, I felt no heat whatsoever...on any internal part. No heat anywhere, which was such an awesome feeling. When I go to put it back together, I somehow manage to BREAK one of the fins, on the fan...causing it to be uneven...loud, noisy, and cause lots of vibration. Sadly, I had to cut the cables to the fan to get it quiet again.

So instead of admitting defeat...tomorrow I will be finding a 80mm fan out in the garage somewhere, and using that instead. Should be a little smaller, quieter...and maybe more powerful. I should also have a grill for it somewhere as well, even though I just bought a 60mm grill...grrrr.

New photos and video tomorrow I suppose...not like I have anything better to do on a Monday evening.
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post #8 of 8
Thread Starter 
Replaced the fan and is now almost silent, and still just as cool...or even cooler! Photo and video in first post.
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