Modified Ender 3 V2 Hotend enclosure to allow 40x20mm fans

thingiverse

Many popular hotend fans that run silent are 40x20mm versus the stock 40x10mm model in the existing Ender 3 V2. Unfortunately the stock Ender hot end assembly shroud cover is too cramped to fit one. What I have done here is to modify the Ender 3 V2 cover to allow room for a 40x20mm hotend fan (such as the Noctua A4x20 FLX), in addition to other changes to permit 3D printing without supports. The benefit of using this model is that it's backwards compatible with stock, and you will not have to change anything else whatsoever. It also resembles the stock shroud closely. You will need to hot sink brass threads, similar to the original part. The source CAD from Creality that I based this off of appears to have some inaccuracies in boss location, so therefore you might need to adjust the position of two of the threads subtly by nudging it into the correct position while heating it with a soldering iron tip. It's not difficult to do. You can optionally sink M2 threads into the bosses meant for the hotend fan. You can go larger with M3's at this location for convenience. You can also drill these out if you wish to use the Noctua silicon bosses. Please note that the plastic posts for aligning the blower unit work better in the original ABS injection molded part than they do in a printed part. They will line up fine, but frequently snap. In the future I intend to replace these with some M2 screws, and I invite anybody to remix this model to both do the same as well as make any necessary adjustments to improve accuracy.