How to Prevent Your XBox 360 Nyko Intercooler From Melting/burning Your Xbox

If you have an early XBox 360, you probably know that there's a horrible design flaw Microsoft didn't have time to properly test and fix-- the system at times can get so hot that the logic board inside cracks. Microsoft, sensing pending class action lawsuits, extended warranty by three years.

The Nyko Intercooler is a possible solution, since it keeps your xbox cool. This cooling unit plugs into the back of your 360 using the 360's power supply. However, there's an ironic problem. The Nyko Intercooler is also badly designed ... and also melts. The problem is that the 360's power supply at times uses so much juice that the Nyko's adapter melts.

Also, because the 360 wasn't designed to power a separate set of fans, it sometimes does not get the power it wants and games crash. Bummer! (happened to me within 5 minutes of use without this mod).

The obvious solution is to rig it to use it's own power supply! My method involves getting an AC/DC adapter so that you can get juice from your wall. I found another design that uses 12v batteries. [link]
http://forums.xbox-scene.com/index.php?showtopic=602647&st=0[/link]. I personally prefer my design, because you don't need to worry about getting new batteries all the time!

Step 1: What You'll Need

The tools in this project are pretty straight forward. You don't /need/ to know how to solder, but it would REALLY help. You can search for soldering tutorials on instructables. The soldering skills you'll need are beginner.

The Nyko is set up very simply, it's just 3 fans all wired together. However, you may need to do some very simple calculations to get the correct power supply.

I = P/V
For 12v you'd do this: (1.44 * 3)/12v = 0.36A

In other words, if you use a 12v power supply you should get at least 360 mA. You can get one at radioshack, and those two numbers are blatantly visible on the packaging. I used a 9v, and for that you'll need at least 270mA. I'll assume you'll get a 9v with at least 270mA for this instructable.

Thanks to my pal Joe for helping me with the math. Anyhow, I managed to run this on 3 AAA batteries so we based the math around that.

Tools and Supplies
Wire (I used thin wire wrapping wire)
Solder
Solding Iron
handsaw that'll cut plastic
9V AC/DC power adapter with over 270mA
Female adapter for that power supply (device specific)
Electric tape
Phillips head screw driver
Wire stripper (you can use your teeth)

Step 2: Open It Up

Unscrew the Nyko in the back and remove all its guts. There'll be a bunch of screws, the packing and a power adapter thing.

You'll be left with the power source adapter connected by two wires form the fans. One wire is 3 red wires connected and the other is the black ground wire. Cut both of them at the tips.

Step 3: Cut the Sucker!

Ok. So, I originally though that you could just drill another hole in the back of the Nyko to fit the 360's power supply. Well, it doesn't fit. That's why there's a huge hole in it in the picture (below).

The best thing to do is to cut the bottom portion of the Nyko adapter off. Saw it off right above the old power supply hole. In other words, cut off the piece below the fans!

Step 4: Solder and Finish!

Use the photo for help with this step. It's actually very simple!

Connect the wires to the female adapter
Expose ends of your wire and the Nyko wire, and wrap your wire around the Nyko's wires. Okay that doesn't make any sense... just look at the picture! Do the same to the female adapter.

Here's a hint about soldering. Wrap the two exposed wires together first so it's stuck on there. Heat up the joint with your soldering iron and stick some solder in. It does the job!

Give a test but plugging it in. They should go fassst!!!

Reverse Polarity
I had no problems with this, but be warned. I haven't checked if the fans can get this problem. The fans need to blow out. So if when you get this working and tested they're sucking through the grill, reverse your wires!.

Step 5: Finished!

Ok, stick it on your xbox, plug it in and play some Bioshock!!!

Alternatively, you can also drill a hole into the side of the Nyko big enough for the female adapter to stick through. This way you won't have all those wires hanging out. I didn't have my drill anymore, so my setup will suffice for now.