A short time back I was shopping around for a new router. After some comparison shopping I decided on the Linksys E3000. (UPDATE: Read more on this at Cooling the Linksys E3000 – Part 2 – Inside the box)
However, I was having issues with my Wii randomly dropping off the wireless network. I started troubleshooting and accidentally happened on something that bothered me: This router got HOT. By hot I mean I checked it with my infrared thermometer and I got a reading of 61C from the bottom of the router. That’s well above it’s operational temperature rating of 40C.
First, a note on my configuration:
- DD-WRT v24-sp2 (12/19/10) big (e2k-e3k)
- 2.4ghz and 5ghz access points, both in use
- A single gigabit device on the wired lan.
I had a good deal of network activity going at the time, so I took most of the devices off the network, powered off the router for about 5 minutes, turned it back in and checked again. No measurable difference in temperature after about a minute of operation.
My concern was that the router was simply too hot to continue operating like this. I was afraid of chipset failure.
I started in on a mod idea, with a couple of points:
- The router needed to be cooled quietly
- The router needed to be cooled in a way that wouldn’t void the warranty in case I ended up RMAing it.
I initially thought of driving a fan from the DC-in connector, but the barrel shape made it difficult to come up with a clean mod, and at 12 volts, it could get a little noisier than I wanted it to be. I wasn’t using the USB port, and that’s an easy 5v supply to a fan, clean and easy.
So I started with a simple USB-to-fan cable. Pulling the 5v supply off the USB port and to a fan connector was easy, and after a quick check with the multimeter said it was good to go. It worked great, but I found out that unfortunately none of the fans I had lying around ran at 5v; they were all 12v fans. I would have to buy a fan for this.
I figured a 120mm fan would give me good air flow at a low noise rate, along with covering most of the bottom of the router. A quick search turned up a Coolerguys 120mm USB fan. A 5v fan with a USB connector to boot. Oh well, I still get to keep my cable for another project :)
So I ordered the fan. It arrived quickly (not quickly enough, I was impatient! ;) ), and I started in on making it look nice.
Removing the grill from the fan was the first step, and it came off easily with a #2 Philips screwdriver.
I had some adhesive foam feet lying around from something else, and cutting them in half and stacking three gave me a nice fit with the finished feet measuring 25x20x28mm.
I added some 4mm rubber feet to the bottom of the fan to give it intake room, and test fitted it. It couldn’t have worked out better. The fan fit neatly under the router and ran quietly — I could barely hear it even when the room was completely quiet. The 4mm rubber feet allowed enough intake room under the fan, even though the fan could have easily moved more air with more of an intake space.
The result? A reading of 30C — That’s a 31C drop in surface temperature! Of course, if you do this, make sure the fan is blowing up into the bottom of the router; not down.
The Wii? As it turns out, it was in a spot where it got terrible signal to begin with. A wired adapter fixed it’s issue.