SS Battlestar....attempt II

[star-art]

Here's a minor update. I created some special adapter plates for installing the fans. I chose some of the finest computer case fans available. They are very efficient and super quiet. But, as you will see, there is only a tiny mounting surface around the perimeter. This made it impossible to apply weatherstripping to seal around it. Fortunately, I was able to come up with a good workaround.

The solution was to secure each fan to a custom adapter plate via silicone caulking. Then, the assembly is bolted to the front engine bulkhead by way of elastomer anti-vibration mounts. You could argue these aren't absolutely necessary. But, given this is an all-Plexiglass structure and fans do create at least some vibration, I prefer to be better safe than sorry. All my builds are made to last and this is the sort of extra effort I like to go to.

At any rate, the anti-vibration mounts stand proud of the surface of the bulkhead. The resulting gap was filled with weatherstripping to make a draft-proof seal. I finished by hooking up the fan to my 12V benchtop power supply for a test run. It was so quiet I had to listen real close to even hear it! And, it moves a lot of air.

As I was installing all this, I tried to think ahead to what might happen if a fan ever quits working and has to be replaced. Once the front sloping panel goes on, there's no way to access the screw heads on the other side of the bulkhead. I could imagine it being a nightmare to work on later. This is often the case with products you buy that are designed to be easy to put together at the factory even if that means they are impossible to service later on.

Well, I just don't believe in that sort of thing. So, I managed to install jam nuts inside the anti-vibration mounts using thread locking compound. This turned the loose mounting bolts into fixed studs. This way, each fan can be removed and the mounting bolts will stay put. Just twist off the lock nuts, slip the fan off the studs, and replace it.

BTW, I used rubber washers on the back side of the bulkhead so the mounting bolts do not make direct contact. This plus the anti-vibration mounts isolates the fans from the surrounding structure to ensure the smoothest possible operation.