So for the last year or so I have followed the issues discussed about fan balance on the 1100 in particular and the potential vibrations that could result. I didn't think that my machine was particularly noise or out of balance so I just rocked along with the stock fan, A previous post got my interest up over the holidays and I decided to put something together to address the issue.
I installed the first version of the fan kit and the difference in sound and vibration is huge. The only sound now even at 5140rpms is the whine of he VFD. There is a very slight vibration but this I believe is coming from the unbalanced Spindle pulley.
I modeled a replacement for the motor end bell keeping the same general configuration and mounting points. To this new end bell I spliced a housing to integrate a 120mm fan. I used a Noctua Industrial 12VDC fan since I already had 12VDC available in the mill headstock. I used the Austrian Noctua fan because of its reliability. I have replaced a lot of fans, but I have never replaced a Noctua fan.
The model was the converted to an .stl file and printed on my Rostock Max V2. The fan and grill were installed in the new printed motor end bell and the entire assembly fixed to the motor using the same mounting with longer screws. The end bell consumes about .5+kg of filament and takes about 15 hours to print
The airflow over the motor is continuous and runs anytime the machine is powered. The volume of air produced is ample and seems to keep the motor very cool. I cycled the motor from low to high speed and back down continuously for about 5 minutes. This essentially keeps the horsepower meter in the yellow all the time and there was no perceptible warming of the motor.
I am quite happy with way this all turned out and looking back I should have done it long ago. There are some small changes that I will make to the model like adding extended bosses below the flange mounting bolts but all in all the fit was quite good with sufficient clearance between the end bell top and the door switch to slide into place without removing the door switch, I also intend to take some Flir photos of the motor to judge the cooling efficiency during a long term run just to be sure.
I have also considered offering the kit or kit components for sale if there is an interest.
gary