I love my Samsung VR. However, while using this device, I find my phone gets very warm.
This cover uses the same power from the phone's charger to run a fan and also charge the phone while in the VR.
Step 1: Step 1: Print the STL, Gather Other Parts...
The STL file takes a few hours to print.
I printed mine with 0.1mm resolution at 85% infill with the flat-side down.
The fan I used was a recycled 5V 80mm brushless fan from an old laptop cooler stand. (Any fan can be used, as long as it is 5v and 80mm in diameter.) I simply disassembled the fan parts and set them aside.
The USB spitter can be purchased here: http://amzn.to/1Y20Jgi
I particularly like this cable because it had a dedicated line used specifically for bluetooth headsets. For this project, it will power the 5v fan and still allow the phone to use its 'fast charge' feature!
Step 2: Step 2: Clean Up the Print/install the USB Cable
Depending on your printer, this may be optional. The print may need to be cleaned of 'webs' if there is some nozzle leakage.
After the print is cleaned up, the assembly can start! Lets start with the USB cable.
The usb cable needed will have a female end, and two male ends. One will be longer than the other. The female end will receive power from the wall charger, and power both the fan and pass power to the GearVR as to charge the phone.
One of the usb cables will need to be cut in order to solder a source of power to the 5v fan. In this case, the shorter cable will be cut near the end. Remove the outer jacket to expose an inch of red/black wires. These will be stripped and soldered to the positive and negative terminals of the fan board.
After soldering, the coil should be installed as the picture shows. The sleeve bearing from the brushless fan is then pressed into the center of the plastic hole, which should lock everything in place due to the expanding plastic.
Step 3: Pop on the Fan
The fan should slide into the bushing that's been pressed into the hole on the print.
Any parts of the fan that were removed can be installed now (for me, it was a rubber o-ring and a plastic snap-washer to hold everything together.
Step 4: Put It All Together!
The wiring can be checked by plugging in your phone charger into the cover.
The fan should spin!
The second wire from the USB splitter plugs into the VR goggles and will charge the phone while in use.
The tabs should install the same way as the original cover.