Hello Ihibrgr (and doesn't that come trippingly off the tongue) 🙂
Wow! Excellent details here. How I wish I had had such resources available when I started out.
However, I seem to have worked mostly on the G1 series of units (A1254) but without necessarily noting the Logic Board numbers. My first unit had the DELTA PSU installed and whilst it is more robust than the Flextronics unit and does not seem to succumb to heat stroke quite so readily, it still ran boiling hot, way over 40 degrees C topside outer case temperature. A second unit used the Flextronics PSU and ran a couple of degrees warmer. See the IR pictures on Ray's site:
http://sites.google.com/site/lapastenague/a-deconstruction-of-routers-and-modems /apple-time-capsule-repair/apple-time-capsule-fan-mod/infra-red-pictures-of-time -capsule
I have noticed that different units vary considerably (even within the same generation type) when using the wifi link for large file transfers. The temperature differences can be as much as 5 degrees C. I have not dismantled any unit to establish why, working on the old adage *"If it ain't broke, don't fix it"* (Grammar? wots that?) So my research is observational only, for what it's worth.
I can only assume you mis-typed when you mention a 1/2" hole for the fan? A bit tiny surely? Or is that 1 1/2", which would be a better fit. I use 44mm, which I think is nearest fit to 1 3/4", which is almost a 'Grand Canyon' in proportion to the fan opening.
Did you tape over the other side of the fan? This stops air circulation around the fan edges and makes the airflow through the PSU, possibly, more efficient. There was a lot of trial and error with my two TCs on this point and DAYS and DAYS of temperature monitoring before the 'balance' was felt to be correct.
Ray favours cutting away the side of the fan, with it in its original position and whilst this did increase air-flow through the PSU, it was not as good as turning the fan over, but it is a close run thing.
I slow the fan down with a 33 Ohm 1/2 Watt resistor, since I was trying to get it as slow as possible (to keep down the noise). 45 Ohms seemed to be the limit but occasionally I would have a fan not start-up. 15 Ohms at 1/8 Watt will overheat I think, presuming the fan load characteristics are linear - I calculate 0.4 Watts for the resistance.
Does the fan run much slower at 15 Ohms? I never tried that small a value- maybe I should? My aim is to have speed of fan-control proportional to temperature inside the case. Getting the very small connectors is the bugbear there though, they are very hard to obtain.
An absolutely wonderful addition however, thanks so much for all this data. It must have taken ages to compile?
I hope tests continue and you add more info again.
Regards,
Chris Fackrell,
YORK,
UK