Ya gotta do, what ya gotta do. So long as it gets the job done.
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Ofcourse I know it would void the warranty. Im just theorizing and wouldnt do it anyways since the fan noise doesnt bother me, but for the modders anything is possible. You say the waterblocks would have to be custom made.... isnt that why we all bought welders...
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Disconnect your fan on your welder then Just buy a cheap window ac unit put it on a table outside, build a plenum chamber to round dryer hose and pipe it to your welder never worry about over heat and the noise is outside. Paint ac unit green also. Wrap hose in carbon fibre tape for that racing look.
The ultimate mod rofl
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I have a water cooled computer and it is quite it has a radiator 6W x 16H x 1.5 thick It keep it very cool I have look at it as a way to keep the noise down. Making a water block would not be hard I will have to wait till the warranty is up before I make one for my 250EX
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I see condensation problems with a setup like that.
With an "always on" fan you get used to hearing the noise and if you turn it on and dont hear the noise you know the fan is out/not working. If your trained without the noise you will start welding and only after damage will you find out that your temp sensor or fan is bad.
Dirt, dust and grindings are hard on welder that move a lot of air thru them you should clean them once a year or so to keep them from over heating or short out from grinding dust. A plasma cutter in shop makes a lot of dust and smoke best keep all other machines off will cutting.
I use my fan to remind me to shut off the gas. When the welder gets turned off the gas gets shut off. Since it's loud, there's incentive for me to get off my lazy arse and shut it all down when I don't need it for a while.