Your post inspired me. I printed off a fan adapter for the rear exhaust port and mounted a Noctua 60mm. (Ialso reaplced the center fan). Did you cut the rear of your enclosure? It looks like you have a large, open square hole where my box has a smaller, gridded round hole. Either way, I’m not sure my setup is providing enough airflow. I can barely feel anything coming out and it will just barely push away a strip of paper held loosely over the hole.
I printed ABS the other day for the first time since swapping the fans. Of course, the loud power supply fan runs full time while it’s supplying enough juice to keep the nozzle and bed that hot. After awhile, I started noticing a little odor with my nose near the rear of the control box (a foot or so away). Not exactly burning, but definitely smelled of plastic/rubber being heated up pretty hot. It never got worse, never smoked or gave any problems. Still, that worries me.
Your later comment about a 120mm fan caught my attention once again. After some measurements, it appears there is no room inside the cabinet for fans that are any larger at all. For the cabinet itself, I suppose that if the cable bundle at the right rear (with the control box upside down and the bottom removed) could be re-routed to make room for another 60mm mounted to the side. Suitable openings would have to be created obviously, and that still doesn’t solve the problem of the noisy power supply fan. I haven’t been able to find a single high-quality quiet fan that’s thin enough to fit in that location.
Here’s what I’m considering, and was hoping for some feedback. As you suggested, I would eliminate the other fans and plug the rear exhaust port. I would cut a large hole in the rear side of the cabinet and re-route the cables. I’d then mount an Artic F12 120mm fan to the outside. These are cheap, get great reviews, and move 74 CFM on the highest speed. I would remove the power supply fan and create a seal between that inlet and the inlet on the bottom of the control box using some foam weatherstripping. I figure I’d also need to fashion a baffle plate somehow between the front of the box and the rear to force the air to flow through the power supply instead of bypassing it.
My main concern here is that I can’t think of anyway to make sure that enough air is in fact flowing through the power supply. I’d never know if it’s cooking until it’s too late. I would really like to measure the internal temp of the power supply both with the stock fan and after the modification. Thoughts? Thanks for any feedback!