How to: Make simple dual 5V, USB powered fans for your Bucket.

[MoSc0ut[TK]]

Here's a quick tutorial on how to add some ventilation to your helmet.

 

*EDIT - I just noticed CheckWan had posted a similar thread in April (I didn't scroll far enough) but if you prefer a photo step by step here you go. Also I found my fans on AliExpress, 5 for $6.50 with free shipping. Shipping took 4 weeks from China to the US but at the time I was still building my armor so I didn't need them right away.

 

 

I used this set up on my first troop that was a 1 1/2 mile parade in 96 degree heat! It was still horrible but this helped me make it through!!

 

Here's what you'll need:

 

-2x 5v two wire blower fans

-USB cable

-5v cell phone charger

-Soldering iron

-Heat shrink tubing

-Wire cutter/stripper

 

First cut the USB cable to desired length. There will be some outer protective wire and foil electrical shielding as you work your way towards the 4 inside wiring.

 

There should be 4 colored wires. Red, Black, Green, White.

 

 

Clip off the green and white wires (they aren't needed) and strip the ends of the black and red.

 

 

Clip the small plugs of the 5v fans and strip the ends.

 

 

Twist together like colors.

 

 

Slip the appropriate size heat shrink over both the USB cable and the ends of the fan wires.

 

 

 

**Important step** TEST THE CIRCUT!! Make sure it works before proceeding. The first one of these I made I went through testing the voltage and figuring out which wires were what. In the 4 I've made this far the colors have been the same but that doesn't mean there isn't some off brand USB cable with weird colors inside.

 

 

Solder together like colors.

 

 

 

Slide heat shrink over soldered connections and heat shrink.

 

 

Slide larger heat shrink over both and shrink. This gives it all a cleaner look and added strength.

 

 

Power provided by one of these.

 

 

I got approximately 2 1/2 hrs run time from one of these fully charged. The whole set up doesn't weigh much and was added to my bucket with a few pieces of industrial strength Velcro on a mounting bracket I made with some styrene sheet I had from another project. The battery nestles in the back hump with a bit of Velcro quite well.

 

 

-FIN

 

 

Jim - TK50899

Edited June 22, 2016 by MoSc0ut

[JAFO[TK]]

Nice tutorial 

 

You did well to get 2.5hrs for two fans from a 2600mAh power bank. I only get about 1.25hrs. Just goes to show not all power banks are created equal.

[themaninthesuitcase[Admin]]

Running a single fan (I've got mine individually switched) I got well over 5 hours. I do need to do a full test and see what I can get out of them.

[JAFO[TK]]

Here's what I got...

 

2600Mah / 1A

1 Fan - 3h 45m

2 Fans - 1h 20m

3 Fans - 50m

 

Like I said, not all batteries are created equal!

[ask382]

this should be a rather easy math exercise

 

2600mAh batery, 1 A Draw =

 

2600mAh = 2.6Ah

 

1Ah/2.6Ah = 2.6h

 

so if the batery is working as it should, and the fan has no "exsess" Draw, it should run for 2.6 hours, wich we can round Down to 2.5 hours, wich leads me to belive that the fan probably doesn't Draw exsactly 1 A

Do you know the Wat output of the fan??

if it is rated at 1A an​d the battery is 5V then it should be P = U x I wich is 5V x 1A = 5W

 

Given Your times, I'm guestemating the fan is about 3.5W - 4W wich  i figgure from 2.6Ah / 3.5h = 0.742Ah wich again is 5V x 0.742 = 3.71W

 

Then there is the resistance of thhe wires themselvs to considder, but given the short length, we can safely asume it doens't realy affect the use time

 

The Math is sound, but then again, it might just be wariations in the powerbanks

[JAFO[TK]]

Never had time for maths. I just buy a bigger battery

[zv288bot[TK]]

Great step by step tutorial BUT of course with recent events, inquiring minds want to know more about your bracket they are mounted on. Can you show some pics.

 

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[Cricket[TK]]

Great step by step tutorial BUT of course with recent events, inquiring minds want to know more about your bracket they are mounted on. Can you show some pics.

 

 

I could be wrong, but to me, it just looks like a piece of white ABS cut to fit in there as the bracket.  

[MoSc0ut[TK]]

Here's my setup with my home made bracket.

 

 

 

A little gaffer tape to keep the cords tidy. This was my first one and I made the wires a bit longer just to be safe.

 

And these are the specs on the fans:

 

Black Brushless DC Cooling Blower Fan 5015S 5V 0.1-0.3A

 

I went with the lowest draw fans I could find to maximize the run time, especially since the plan was to run 2.

 

 

Jim - TK50899

[zv288bot[TK]]

Great job! Thanks so much!!

[nukem25rs[TK]]

That looks really good!  I've been wondering exactly how to make the bracket. one idea to use instead of the gaffer tape would be to drill a small hole(you could even use a small file to make it the exact size rectangle) on each side of there the wire needs to sit and use a small size zip tie through them with the zip on the wire side of the battery.. a little cleaner but a bit more permanent.  

 

Mike

[MoSc0ut[TK]]

That looks really good! I've been wondering exactly how to make the bracket. one idea to use instead of the gaffer tape would be to drill a small hole(you could even use a small file to make it the exact size rectangle) on each side of there the wire needs to sit and use a small size zip tie through them with the zip on the wire side of the battery.. a little cleaner but a bit more permanent.

 

Mike

Great suggestion Mike! I was also thinking to add a couple Velcro cable ties either end then I could keep the wires tucked away minus the gaffer tape.

 

 

Jim - TK50899

[kman[TK]]

Here's what I got...

 

2600Mah / 1A

1 Fan - 3h 45m

2 Fans - 1h 20m

3 Fans - 50m

 

Like I said, not all batteries are created equal!

 

Not all fans, too.  I got 9.5 hours for one fan with my 3000mah battery pack!

[Sly11[Admin]]

If you are running 5 v fans or 12v for that matter, try and get the lowest amperage you can.

.06 amp is good for fans speed and run time. Many of them state .1-.3 amp.

 

 

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[Yiyo[501st]]

I use the Aker 3350 and excellent results for now!

 

 

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[MoSc0ut[TK]]

UPDATE: So I did a small upgrade by adding a small switch. This way I can not have the fans spinning as I stick my head in my bucket.

 

First I made a small mounting bracket out of some scrap ABS.

 

 

...and mounted it to the fan bracket/insert.

 

 

A little surgery on the USB cable to find the negative (black) wire.

 

 

Added some short, 22 gauge, lead wires and heat shrink to the switch before attaching to the wire.

 

 

Installed. Battery now rests in the chin instead of the back bump. This helps keeps the helmet from riding back too.

 

 

 

 

Enjoy!

 

 

Jim - TK50899

[kman[TK]]

Nice job! I like the little clip you made for the battery pack. I need to figure out some good way to keep mine in place, instead of just stuffing them under the fan bracket.

[MoSc0ut[TK]]

Nice job! I like the little clip you made for the battery pack. I need to figure out some good way to keep mine in place, instead of just stuffing them under the fan bracket.

That's actually a piece of the hook side Velcro that's adhered to the battery. The loop side is stuck to the inside of the helmet. However your comment has given me an idea! More to follow.....

<evil laugh!>

 

 

Jim - TK50899