I been using dual 50mm fans in my fursuit head for quite some time now but one of them failed during the last DJ at the dead dog dance on Sunday night at TFF 2024. It stopped spinning, got quite warm, and then finally fell apart with blades and hub popping off the spindle, leaving me with just one functioning fan.

It happened toward the end of final DJ so I didn't get all that hot as the one fan kept me going just long enough until 1 AM (I think) when the music finished. I did wanted to hang around the main convention floor space as there where still plenty of furs mingling about but alas, running around it half the fan cooling didn't appeal to me all that much.

I had some extra 50mm fans but I couldn't find them (bought them a while back and didn't find them where I though I stored them. I gave up looking and I ordered a new set as a local furmeet was coming up soonish. The replacements didn't arrived in time but I did find a longer 12V 50mm fan that I temporary used in the meantime. It protruded and touched my face in the head but it wasn't that bad and even though I ran it at 5V, it had just enough cooling effect to be useful. Beside, it wasn't super hot anyway.

The new set of 50mm fans did arrive in time for another local furry event and I got them installed for it. But at the same time I ordered the 50s, I also took the opportunity to also order some Noctua fans as they have very good reputation for being reliable, quiet, and high performance. Unfortunately, they do not make a 50mm in 5V and I did want to settle for a 40mm again. So I upped to some 60mm ones.

The larger size meant I had to completely redesign the fan frame to accommodate them while trying not to make the whole thing not too much bigger than the old 50mm frame. I had to do a lot of trimming from the top and bottom as well as adjust the side extensions down to keep the overall size down as much as I could, which I barely managed to do. The result was slightly larger but it did (barely) fit inside the head.

I did have to remake the side extensions so a part of it overhand the front as the foam from the inside of the cheek area would rub the fan blades if it shifted a little (I found this out during the last furmeet at the park but wasn't too bad if I was careful). I reprinted the new design and did some quick tests and it seemed to do the trick. The real test would be at the furmeet coming up at the end of the month but I am sure it be fine.

The new, larger fans do pull a bit more air. Noctua did specify the flow rating to be like three times of the generic 50mm I used before though it didn't feel quite that much of an increase probably do to some restrictions being inside the head. But definitely more. The new set are quieter that the lower frequency humming sound particularly nicer than the high pitch coming from the older ones and especially compared to the whine of the single (and higher RPM) 40mm I had before that. Though the sound from none of the fans I used was all that noticeable when I am in crowds of people like at the meets and cons, just when I am along in a quiet spot.

Some notes of the 3D printed frame I designed. I broke it up into six parts - the upper and lower main body, the two inner brackets, and the two outer extensions/fan shields. The brackets ar exactly the same as well as the extensions, just flipped. The main sections are slightly different. The lowwer part has a chin rest protrusion in the center that I glued a foam pad onto. The upper has a notch to add clearance for my upper lip and nose that I also applied a foam pad. I later glued some thick fabric over the foam that is not shown in the photo so it would be a little softer. I might add more layers later if I need it. It is very close to my face and I might need to extra cushion. We shall see.

By the way, the fans not only help in cooling, but keep my glasses from fogging up inside the head. I do have enough room to have them on though they are a bit tight. The new design is a little wider than the older setups and it does allow a little more clearance so my glasses does not press against my face as much as before. It also spreads the head a little flatter, giving it a better look than to the more narrow appearance when I first made the head (check out the ancient pics in my gallery to see the difference).