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
- Jigsaw/handsaw/holesaw etc
- Drywall saw (for ceiling if required)
- Packing Material (can be clothes, old cushion filling etc)
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
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