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How to Mod a Kuhler 620, Properly
- also applies to most AIO's not designed for expanded use.
Everything here is at your own risk. I have no idea if warranty will be affected.
Please forgive the quality of these pictures. I am using my Galaxy S4 phone. I had settings enabled which took away from the quality and performance, so future pics should be a lot better.
I am writing this one in its own post in case anyone wants to link to it directly.
Let me just start off by saying you do not need to cut the tubing on an AIO to mod it. there is nothing special about how these coolers are designed, they follow the same technology of any other water cooling design.
To start you will need some tools:

You do not need to unscrew any bolts on the pump block. You can unscrew the two screws seated directly next to each elbow barb if you'd like to take the barb connector out of the pump. I did not. All in all it took me about 15 minutes to do this.
At this point I first removed the tubes from the Radiator and emptied the Glycol coolant into my container (glass cup). A little out of order but it will all make sense, I promise.
The thick plastic looking band around the tube end first needs to be loosened. To do this take your lighter and lightly wave the flame around the rubber. Do Not leave the flame on the rubber, you only want to warm it up a little. I waved the flame back and forth a few times, it doesn't need much heat at all.

Now with your Small Screwdriver slide under the rubber cap and gently work the screwdriver around the tube to loosen the rubber cap. If you let it cool it will tighten back up. Apply a little heat to soften it again.

With a firm hold start wiggling the end of the tube back and forth while gently pulling. The plastic elbow is a Barb so you need to slide the tube off the barb. Using the large flat screwdriver you can gently push the tube to get it going a little easier. Once the tube is off the plastic barb elbow it will look like this...

Do the same for the other tube connector. The same process applies to the Radiator as well. The Radiator barbs are a part of the radiator and are made of metal, so you can give them a little more muscle, but they are still easy to remove with a small amount of force. Wiggling is the key to sliding the tubing off the barbs.
That rubber end cap sits free and can be easily taken off of the pump assembly. Keep these! You will need them if you decide later to return the AIO back to its original design. I put them in a small bag and stored them in with my box of bolts.
This is what your Radiator will look like.

A shot of roughly how much Glycol coolant is to be found in the Kuhler 620. Don't drink it!

Everything disassembled! No need to cut the tubing, and no damage done to the unit which is now ready to be used in your custom water cooling loop.

Up next is testing of a custom loop. Adding your own tubes, a reservoir, and how to get it all working.
- also applies to most AIO's not designed for expanded use.

Everything here is at your own risk. I have no idea if warranty will be affected.
Please forgive the quality of these pictures. I am using my Galaxy S4 phone. I had settings enabled which took away from the quality and performance, so future pics should be a lot better.
I am writing this one in its own post in case anyone wants to link to it directly.
Let me just start off by saying you do not need to cut the tubing on an AIO to mod it. there is nothing special about how these coolers are designed, they follow the same technology of any other water cooling design.
To start you will need some tools:
- Small flat head screwdriver
- A larger flat head screwdriver (optional but useful)
- A container
- An AIO unit - duh
- A Lighter
You do not need to unscrew any bolts on the pump block. You can unscrew the two screws seated directly next to each elbow barb if you'd like to take the barb connector out of the pump. I did not. All in all it took me about 15 minutes to do this.
At this point I first removed the tubes from the Radiator and emptied the Glycol coolant into my container (glass cup). A little out of order but it will all make sense, I promise.

The thick plastic looking band around the tube end first needs to be loosened. To do this take your lighter and lightly wave the flame around the rubber. Do Not leave the flame on the rubber, you only want to warm it up a little. I waved the flame back and forth a few times, it doesn't need much heat at all.
Now with your Small Screwdriver slide under the rubber cap and gently work the screwdriver around the tube to loosen the rubber cap. If you let it cool it will tighten back up. Apply a little heat to soften it again.
With a firm hold start wiggling the end of the tube back and forth while gently pulling. The plastic elbow is a Barb so you need to slide the tube off the barb. Using the large flat screwdriver you can gently push the tube to get it going a little easier. Once the tube is off the plastic barb elbow it will look like this...
Do the same for the other tube connector. The same process applies to the Radiator as well. The Radiator barbs are a part of the radiator and are made of metal, so you can give them a little more muscle, but they are still easy to remove with a small amount of force. Wiggling is the key to sliding the tubing off the barbs.
That rubber end cap sits free and can be easily taken off of the pump assembly. Keep these! You will need them if you decide later to return the AIO back to its original design. I put them in a small bag and stored them in with my box of bolts.
This is what your Radiator will look like.
A shot of roughly how much Glycol coolant is to be found in the Kuhler 620. Don't drink it!
Everything disassembled! No need to cut the tubing, and no damage done to the unit which is now ready to be used in your custom water cooling loop.

Up next is testing of a custom loop. Adding your own tubes, a reservoir, and how to get it all working.