Introduction: DIY Dewalt Cordless Fan

Picture of DIY Dewalt Cordless Fan

How to make this super awesome cordless / corded portable fan that will works with the batteries of your favorite power tools brand , and for less than 50$. In my project im using the dewalt dcb090 adapter. This fan normally operate with 6 "D" batteries, which is not convenient when you need to recharge and replace the 6 batteries. Now it's so easier, and if you are like me and have multiple batteries for your tools, you will have almost infinite runtime on your next camping trip, at the beach or on the jobsite!! Bring this diy cordless fan anywhere to fight the summer heat. ☀️

You will need to use the o2cool 10" fan : model FD10002A, to make this mod. Im also using the dewalt dcb090 adapter but you can also use the makita ADP05 or ADP06 usb power source, the Milwaukee M18™ Power Source, Bosch GAA18V-24N or any power tool usb adapter. The mounting will be slightly different, but the goal is to have a connector for the battery at the cheapest price possible. I got mine for 11$, check websites like ebay or aliexpress.

This o2cool fan has 2 speed and operate at 9v so im using a DC-DC step down converter ( Model LM2596 ). This board step down the current from 20v or 12v to 9v. Same thing here, check ebay or aliexpress, check for the best price you can find it at 2$.

RUNTIME : at 9v (0.7A), the total output is 6.3W. So with the slimpack 2.0AH (40W), runtime is around 6 hours at max speed, and with the 5.0AH(100W) battery, runtime is around 16 hours!

This tutorial video is available on my youtube channel : SEB TECH DIY

Step 1: Material :

Picture of Material :

Connectors and Conduits diameter is : ½" (12mm)

(4x) 90° Connector ( Plumbing SCH40 )
(4x) 45° Connector ( Plumbing SCH40 )
(2x) "T" connector ( Plumbing SCH40 )
(3x) 11" conduit ( Electrical SCH40 ) (280mm)
(6x) 1"½ conduit ( Electrical SCH40 ) (38mm)
(2x) 2"½ conduit ( Electrical SCH40 ) (64mm)
(8x) ¼-20x¾" (M6x20mm)
(8x) ¼-20 Posilock Nuts (M6)
(8x) ¼ Washers (M6)
(1x) DC-DC Step-Down converter board LM2596
(1x) o2cool Fan ( Model FN10002A )
(1x) Yellow Spray Paint : Rust-Oleum : Marigold color
(1x) Black Textured Spray Paint

Step 2: PVC Base

Picture of PVC Base

Start by making the pvc base using the connectors and conduits listed above! You can see the step by step in my video. We will add the 4 "U" clamps later.

Step 3: Installing the Power Source Adapter

Picture of Installing the Power Source Adapter

Now we need to install the power source adapter on the back of the fan. Like i said, you can use the power source of any power tools brand so go with your favorite one.

I'm using JB Weld Plastic Weld to secure the adapter to the cover. Im also using a chicago screw so it will be super stong and it will hold the adapter and the cover together while the epoxy dries.

Step 4: Before We Paint

Picture of Before We Paint

Let's glue the "U" clamp on the base. I screw the "U" clamps on a simple wood jib so they don't move when i glue thems in place. Once it's done, clamp the fan on the base and drill the holes.

Step 5: Paint the Parts

Picture of Paint the Parts

Step 6: Connect the DC-DC Board

Picture of Connect the DC-DC Board

Connect the power source adapter to the DC-DC step-down adapter. The DC-DC adapter will transform the power of the battery from ( 12v or 20v ) to 9v. Normally, this fan operate with 6 "D" batteries. Theses batteries are connected through a wire to the fan electronic board. We will cut theses wires and connect thems to the output of the DC-DC board. Now the fan will think we have put 6 "D" batteries inside.

Step 7: We Are Almost Done!

Picture of We Are Almost Done!

Let's assemble the base to the fan. Put back the cover on. And for the final touch, dewalt sticker ! ;)

Step 8: Yay!

Picture of Yay!

Thanks for reading this instructable! :) If you want to see more, you can check my video here : Dewalt Cordless Fan video , and if you like my work, please subscribe to my youtube channel! :)

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Comments

GeorgeN82 (author)2017-09-14

Well done build and nicely detailed instructions. You really represent DeWalt :)

I'll have to try this on a few old fans I have laying about.

Robertd212 (author)2017-09-11

So no undervoltage protection or fusing. You build a hazardous machine!

tutdude98 (author)Robertd2122017-09-12

Undervoltage and short circuit protection is in drill battery

Robertd212 (author)2017-09-11

WARNING Potentinally dangerous build.

As far as i can see the electronics from the DeWalt battery holder are removed. This results in two major and dangerous problems.
1. No fusing. Very dangerous in combination with these batteries.
2. No undervoltage protection/ risk of emptying the batteries too far.

Both problems can lead to exploding batteries and firehazart.

jongscx (author)Robertd2122017-09-12

The fusing and undervoltage protection is usually in the BMS of the battery. I have yet to see any batteries from a major manufacturer that just exposed the raw cells to the terminals.

batvette (author)Robertd2122017-09-11

This is true but first off lithium batteries dont explode. They can catch fire. Nicads explode.
Secondly the dewalt charger will probably catch a damaged battery and not charge it. The fire danger for lithium batteries that overdischarge is on the next cycle.
So the rational warning is youre gonna damage your battery if you run it too long.

clazman (author)2017-09-10

epoxy doesn't "dry". It "cures" ;-)

ajayt7 (author)2017-09-10

Wow! Beautiful end product

live4ktm (author)2017-09-08

Excellent idea. Very nice build. Thank you.

deluges (author)2017-09-07

Hey are you a makita man or whaaat

deluges (author)deluges2017-09-07

Nice work btw. I like your attention to detail :)

seamster (author)2017-09-07

Very cool!

I love the build, and the level of brand loyalty is admirable! :)

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