Introduction: Fixing a Old Broken Computer Cooling Fan With a New DC Motor

Picture of Fixing a Old Broken Computer Cooling Fan With a New DC Motor

In this project i will show you how to fix a broken computer fan with a new fan.

I found this computer fan in my junk collection, which was not working. I tried to repair the fan with the same motor but no use, the chip which controls the motor was fried so came up with this Idea of using a new motor.

Step 1: Making Video

You can watch the video of fixing the fan or continue reading for the steps involved.

You Can Subscribe To My YouTube Channel Here : https://goo.gl/ctc8l9

Step 2: Things Required

Picture of Things Required

1. Broken Computer Fan (Fan & enclosure separated)

2. Hot Glue Gun

3. DC motor (capable of running between 5 to 12 volt)

4. USB Cable

5. Remote Button (found this in my junk collection)

6. Deo bottle cap

7. Any container cap (diameter 10Cm)

8. soldering rod, soldering wire & soldering paste

9. Stripper

10. Scissor

11. Super Glue

12. Battery & Battery cap with clips

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Step 3: Motor Attachement

Picture of Motor Attachement

1st Image - Make a hole in the center of the container cap so that motor shaft can pass through

2nd image - Glue the motor to the container cap

Step 4: Motor Cap

Picture of Motor Cap

1st Image - Make a hole in the center of the Deo bottle cap

2nd Image - Insert the USB wire through the hole.

3rd image - Solder the wire to the motor and glue the cap over the motor

4th Image - USB pin configuration

Step 5: Fan Attachement

Picture of Fan Attachement

1st Image - Make a hole in the center of the fan bade

2nd Image - Insert the remote button and glue it

Step 6: Combining the Motor, Fan Blade & the Outer Cover

Picture of Combining the Motor,  Fan Blade & the Outer Cover

1st Image - Attach the fan and the motor

2nd Image - Make some holes in the container cap so that air can flow

3rd Image - Mark the outline of the outer cover on the container cap

4th image - after marking cut the excess with a scissor

5th Image - Glue the container cap to the outer cover (be very careful while gluing make sure the blades are not touching the outer cover

Step 7: Finished Images

Picture of Finished Images

To the watch the video of the testing please go to the step 1 or CLICK HERE

Testing Begins @ 7:03

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Amazon US:

Computer cooling fan : http://amzn.to/2acNUk6

Hot Glue Gun - http://amzn.to/29Y2BU8

DC Motor : http://amzn.to/29Qg9lO

USB Cable - http://amzn.to/2a3wlCS

Soldering Kit : http://amzn.to/29RyXjJ

Wires - http://amzn.to/29Y1kwt

Battery - http://amzn.to/29Y0Shu

Scissor - http://amzn.to/29Y1K65

Super glue - http://amzn.to/29Wvpi1

Wire Stripper & Cutter - http://amzn.to/29RBsm8

Amazon India :

Computer Cooling Fan - http://amzn.to/2a0r3sq

Hot Glue Gun - http://amzn.to/29HEslT

DC Motor - http://amzn.to/29X8X79

USB Cable - http://amzn.to/2a5dCWj

Soldering Kit - http://amzn.to/29P00wv

Wires - http://amzn.to/29GdPBl

Battery - http://amzn.to/29HEp9E

Scissor - http://amzn.to/29P2ECE

Super glue - http://amzn.to/29HHbvK

Wire Stripper & Cutter - http://amzn.to/2a0wBD8

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Comments

tutdude98 (author)2016-07-21

Try to fix that broken wing (not sure hoe its called) becouse fan will vibrate

MakeStuff_MS (author)tutdude982016-07-21

That blade is broken into pieces, No idea how to fix it.
You are right about vibration. While testing at low speed(5 volt) it did vibrate but at high speed(12 volt) vibration is negligible.

ThomasK19 (author)MakeStuff_MS2016-07-21

You can counterweigh it by cutting off parts of the opposite wings. But honestly. I would just salvage another fan since there are so many thrown away.

diy_bloke (author)ThomasK192016-07-24

Agree. It is a nifty repair but for 1.60 euro there is already a replacement

http://www.aliexpress.com/item/pc-computer-fan-80m...

thats cheaper than the motor needed here

MakeStuff_MS (author)ThomasK192016-07-21

Counter weighing by cutting off the alternate blades would work.

Thanks for the help.

wazalac18 (author)MakeStuff_MS2016-07-22

i won't recommend counter-weighing it, you might end up with nothing,
since many fans (like the one above) have odd numbered
blades set.... lol

MakeStuff_MS (author)wazalac182016-07-22

So what would you recommend or any suggestion ?

wazalac18 (author)MakeStuff_MS2016-07-23

take ThomasK19's advice.... "salvage from another(defective) fan" ;)

ThomasK19 (author)MakeStuff_MS2016-07-22

I just notice that you could glue counterweights inside the hollow part of the fan. Again, it's probably not worth while the effort.

ThomasK19 (author)MakeStuff_MS2016-07-22

I'd salvage a working fan from a defective computer ;-)

Otherwise Dremel away pieces from the opposite blades until it does no more shake. Of course that will reduce the fan's efficiency even more.

ThomasK19 (author)wazalac182016-07-22

From a physical POV counter-weighing would work. The issue is not the odd blade count, but how to permanently fix the weight.

wazalac18 (author)ThomasK192016-07-23

it is still because of the odd blade count...
if the blades were on even sets, there's no more tinkering on how to balance or permanently fixing the wieght...
you have given the best and practical recommendation... "salvege another fan" and that will also solve the "in-efficiency problem of balancing ang counterwieghing..... ;)

tutdude98 (author)MakeStuff_MS2016-07-21

Or even better, put small weight on part where wing is broken

MakeStuff_MS (author)tutdude982016-07-22

i ill try putting small weight as you mentioned.

Thanks.

ironsmiter (author)tutdude982016-07-22

Rough up the surface around the broken fan blade with a file, or sandpaper.

clean it really well.

JB weld, or Bondic will make for a very securely fastened balancer. It won't blow as well, with the missing blade, but it should let you run at full speed without the fan tearing itself apart, or killing the bearings.

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