40mm Fan To 60mm fan (for servers)

thingiverse

This monstrosity is what happens when I decide that _dang it_, that server has pierced my ears enough with its whiny power supply fan. Repeat after me: This is not a good idea, really. Modifying power supplies is a questionable activity. Still with me? This allows the adventurer to bolt on a 60mm fan to where a 40mm used to be. You'll need to print the 40mm flange plus either the straight or twisted 60mm flange. Both versions will sit flat on a table when mounted, but neither fit in the 1U form factor (it projects above). Feel free to add more twist if you really want a 1U form factor, but really, at that point a fan on a hose probably makes more sense. For me, it's fine because I intend to leave a half unit between stuff in the rack for wires anyway. The design splits apart to allow installation (the 60mm fan probably won't fit through the power supply opening). It's likely removing the original fan will leave a big gap. Probably should seal that up to not waste your airflow. I used packing tape. Steps: 1. Print 40mm flange, one of the 60mm flanges. Make sure they push together. I had to sand mine a little bit. 2. Select a 60mm fan you like with appropriate voltage. 3. Remove the original 40mm fan. Solder a connector in its place. 4. Mount the 40mm flange to the outside of the power supply using the original screws, if possible. Else use whatever you can figure out. Could consider hollowing out the original fan and using it as a bracket. 5. Mount the 60mm fan to the flange using regular PC fan screws. 6. Feed the fan's wires into the small hole, fix them in place with some hot glue so they don't foul the blades. 7. Solder a matching connector onto the 60mm fan. 8. Seal off any new air gaps. 9. Install the power supply. "Massage" the case as needed. 10. Connect the connector, push the 60mm fan assembly in place.