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Thread: Silent Box Fan Build Guide

  1. Thumbs up Silent Box Fan Build Guide

    Silent Box Fan Build Guide


    Hi Talkers, so as some of you may know, I've been building my own 'Silent' Box Fan made from MDF and after making some mistakes, I feel I have now 'cracked it' with the help of Bud Lightyears original guide which can be seen here - Linky

    Simplicity is key and my original attempt failed because the build was far too complex, Bud Lightyears fantastic guide is the foundation for this one, so do check out both!


    Big shout out to RASTA and Bud Lightyear as they both suggested creating this guide for all the members here now and in the future to read if ever they wish to build something similar

    A very special thank you to my wonderful wife who helped me with the guide and always has my back in whatever I do!


    So firstly the tools, you will need ;





    • 18mm MDF (sizes will depend on your particular fan)

    • Wide thread plasterboard screws

    • PVA/wood glue

    • Jigsaw/handsaw/holesaw etc

    • Drywall saw (for ceiling if required)

    • Drill

    • Speed square

    • Duct Tape

    • Pencil

    • Tape Measure

    • Packing Material (can be clothes, old cushion filling etc)

    • Safety glasses

    • Safety gloves



    Remember Talkers..safety first! I very nearly lost an eye or even worse hurt my wife during the cutting of the ceiling hole for my ducting when the tool I was using wasn't correct for the job and I was not wearing safety glasses, the blade shattered sending pieces of that blade towards me and my wife! ;






    It's no joke and the equipment is cheap to purchase..but you can't buy your eye or fingers back!..don't hesitate and don't be silly, just go get them before you start.



    A kind and helpful member of this forum named AND also advised to purchase "wide thread plasterboard screws" for screwing together the MDF boards, he also quite rightly pointed out countersinking the screws would be ideal, I didn't have a set but if you can get one then do buy a set or even one for this job, he knows his stuff so good to listen to the advice given here



    Right so after measuring up your fan, you can then purchase the MDF, I would recommend a minimum of 18mm thickness though and make sure to give your fan some room in the box for packing material. So for example, if your fan is 20cm x 25 cm x 15cm you can add an extra 15 to 20cm or more on each of those measurements (give or take), depending on how big/small you want your box and you can adjust this for your personal set-up/area.


    Once you know the size you wish to go, make sure 4 of the boards are all the same size.. I then start to join the boards like this using a speed square to make sure they are perfectly straight and square. Use glue to stick them together at the same time as screwing them in ;







    Once all four boards are screwed and glued together, we can now focus on the 'top and bottom', simply measure up the area and cut to size ;






    Now it's time to cut the holes for the ducting for the box. I find the centre of the board by drawing a line from one corner to the other like this, it's fast and simple ;










    I used my jigsaw for this (so the resulting circle was not perfect), I used a compass to make the circle and cut the hole ;






    You can of course get a MUCH better result if you invest in a holesaw and use that ;






    Ok so whichever method you use, cut your hole ready for your ducting ;






    Now we're ready to place the filling inside the box, I've used Packaging Peanuts and clothing..you can use anything you like, clothes, cushion filling or more expensive acoustic foam/Acoustic Insulation if you wish! ;






    Place your fan inside at the halfway mark and attach your ducting (feel free to attach your ducting beforehand then push it through, whichever way you find easiest/best), then add the rest of your filling into the box to cover your fan ;






    Now screw on the lid and that's it!..your very own silenced box fan






    Here is the hole I made bigger in my ceiling, it was the old hole I used years ago, once it was large enough I placed a nice clean wall flange up there too, as the silent box fan will be in my loft








    I hope this helps some members who might be thinking of building one now or in the future

  2. The Following 14 Users Say Thank You to IceCalibur For This Useful Post:

    AND (28-08-19), Bud Lightyear (27-08-19), Clifton (27-08-19), gardro (27-08-19), Gaz (28-08-19), HappyBongmore (10-10-19), hotshot (27-08-19), Mac (28-08-19), Patrice (28-08-19), RASTA (27-08-19), roooot (12-03-20), tlh2496 (03-05-20), WhIpLaSh (27-08-19)

  3. #2

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  4. The Following 8 Users Say Thank You to Bud Lightyear For This Useful Post:

    AND (28-08-19), gardro (27-08-19), Gaz (28-08-19), hotshot (27-08-19), IceCalibur (27-08-19), Mac (28-08-19), RASTA (27-08-19), tlh2496 (03-05-20)

  5. #3

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    Iv just built the same thing it's in the attic now I filled it with rockwool really did a good job nice build m8 nouthing like keeping busy

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    Nicely done, Ice. That's a clean job, well executed
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    Ice shows how its done

    And yes, definitely Makita for the win

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  11. Default

    Cheers guys, really happy you like the guide

    Yep, Makita FTW indeed! lol

  12. The Following 7 Users Say Thank You to IceCalibur For This Useful Post:

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    That's my job made easier

    Thanks Ice. A easy to follow guide. Love it.

    Sent from my SM-G930F using Tapatalk

  14. The Following 7 Users Say Thank You to RASTA For This Useful Post:

    AND (28-08-19), Bud Lightyear (27-08-19), Clifton (27-08-19), Gaz (28-08-19), hotshot (27-08-19), IceCalibur (27-08-19), Mac (28-08-19)

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    Boxed that one of (cringe)

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  17. Default

    Quote Originally Posted by RASTA View Post
    That's my job made easier

    Thanks Ice. A easy to follow guide. Love it.

    Sent from my SM-G930F using Tapatalk
    Really happy you like it bro, and I hope it helps with your build, was you and Buds idea for me to set this up, glad you both did

  18. The Following 6 Users Say Thank You to IceCalibur For This Useful Post:

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    Using that wotsit foam....how silent is the fan now Ice?
    Its the 150l av ordered. N a know they are mega loud.

    Sent from my SM-G930F using Tapatalk

  20. The Following 5 Users Say Thank You to RASTA For This Useful Post:

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  21. Default

    Quote Originally Posted by RASTA View Post
    Using that wotsit foam....how silent is the fan now Ice?
    Its the 150l av ordered. N a know they are mega loud.

    Sent from my SM-G930F using Tapatalk
    Yeah I use those packing peanuts as I had some laying around lol..the fan is silent, you can hear some whooshing from the ends of the ducting but I can't hear the fan at all, 10x better sound wise and worth the time and effort involved, so much cheaper and more powerful than those ready-made ones I reckon bro

  22. The Following 5 Users Say Thank You to IceCalibur For This Useful Post:

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    Quote Originally Posted by IceCalibur View Post
    Yeah I use those packing peanuts as I had some laying around lol..the fan is silent, you can hear some whooshing from the ends of the ducting but I can't hear the fan at all, 10x better sound wise and worth the time and effort involved, so much cheaper and more powerful than those ready-made ones I reckon bro
    Nice 1. My stuffs been dispatched. So we will see what time a got on Sunday after a drop ma boy aff at his maws.

    Sent from my SM-G930F using Tapatalk

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    Neat guide Ice very easy to follow mate well done.
    Should help a few out this!!!

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    Hey ice thanks for the thread it's helped me a lot.
    I was going to make a box in the next few days... But I was going to make mine where the fan intake would draw the air from the inside of the box and pull air from the outside through ducting, rather than the way you have it where the intake duct is drawing air straight from the outside...

    Is there much difference or would it be to noisy or all the same thing?

    I hope this makes sense lol
    Last edited by Greenirl; 28-08-19 at 07:32 AM.

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    Fantastic guide, thank you. May have a go at one of these, so have bookmarked for future reference
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    Would you notice a massive difference mate? Not sure if it's worth doing with my setup. That or I'm just a lazy feck
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  33. Default

    Quote Originally Posted by RASTA View Post
    Nice 1. My stuffs been dispatched. So we will see what time a got on Sunday after a drop ma boy aff at his maws.

    Sent from my SM-G930F using Tapatalk
    Yeah will need a few hours for sure, I'm already excited your stuffs on the way bro

    Quote Originally Posted by Gaz View Post
    Neat guide Ice very easy to follow mate well done.
    Should help a few out this!!!
    Thank you for the kind words Gaz mate, I really hope it does help some members out!

    Quote Originally Posted by Greenirl View Post
    Hey ice thanks for the thread it's helped me a lot.
    I was going to make a box in the next few days... But I was going to make mine where the fan intake would draw the air from the inside of the box and pull air from the outside through ducting, rather than the way you have it where the intake duct is drawing air straight from the outside...

    Is there much difference or would it be to noisy or all the same thing?

    I hope this makes sense lol
    Well the ducting I use is that new and expensive Phonic acoustic ducting, which helps reduce that 'whooshing' along the ducting..so not sure doing it your way would actually reduce the noise, maybe give it a whirl an see how it goes?..good luck!

    Quote Originally Posted by Maccajuana View Post
    Fantastic guide, thank you. May have a go at one of these, so have bookmarked for future reference
    You're more than welcome Macca, I hope it helps and goodluck with the build!

    Quote Originally Posted by UpT0wn View Post
    Would you notice a massive difference mate? Not sure if it's worth doing with my setup. That or I'm just a lazy feck
    It all depends on how much the noise bothers you I guess UpT0wn, to be honest years ago I used a cardboard box and that was better (for me personally) than without anything at all, so this box is even better than that and allows me and the wifey to get a good nights sleep undisturbed

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    Cheers dude, going to be building one to silence this 8" RVK

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  37. Default

    Quote Originally Posted by roooot View Post
    Cheers dude, going to be building one to silence this 8" RVK
    You're welcome roooot, glad it's a help for your build and good luck with it!

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    Quote Originally Posted by IceCalibur View Post
    You're welcome roooot, glad it's a help for your build and good luck with it!
    Thanks bud

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