WRT54GL Heatsink and Fan Mod Tutorial

Discussion in 'Modding Forum' started by MangoMan, Jul 30, 2007.

  1. MangoMan

    MangoMan LI Guru Member

    This is an easy tutorial on how to add a heatsink and fan to your WRT54GL router. I will show you step by step how to accomplish this task.

    Things needed:

    1. 40mm x 40mm x 10mm computer fan (good quality)
    2. 2cm x 2cm x 1cm Copper or Aluminum heatsink ( e.g. video mem hsink)
    3. J.B. Weld Qwik Epoxy
    4. Hot melt glue gun
    5. Soldering gun and silver electronic solder
    6. 30 minutes to an hour depending on experiance

    -First you start off by opening the WRT like shown in the picture below. You pop the blue front away from the black at the red line. Push in the direction of the arrows. There are no screws just a snap in place cover. You will also unscrew the antenas in the manner shown.


    Next you will slide the router bottom from the top so you can see the chipset and wires. You will now mix equal parts of the J.B. Weld together and put a pea size amount on top of the Broadcom chip in the router. Take the heat sink you gathered and push down on top of the chip. Twist the heatsink a few times and make sure it is even and flat making even contact with the Broadcom chip. When you are done you should see something like below.


    We will now add the computer fan to the board to suck cool air from below and push it out the top of the router. You will want to use the hot melt clue gun for this. You will want to hold the fan flush to the bottom of the WRT pcb and glue in the places circled in read to temporarily hold everything in place as shown.


    Flip the pcb over and then mix a new batch of J.B. Weld. We will now apply the epoxy to the locations specified in the picture. Let set and continue on.


    Once again we flip over the WRT pcb and will start on soldering the fan power. Turn on your solder iron and wait till it becomes it's hottest. Cut the fan wire so that the are the exact length needed and strip. In the picture red is your hot and green our your grounds. You can use either one of the green circled stubs for the black wire but must use the red circled stub for your red (hot) wire. I found that I could curl the wire around the existing solder stubs for the power connector on the back of the pcb and it made things easier. You will want to place the tip of the iron on the existing solder stub and then touch the silver solder to the wire and stub. If it is the right temp the wire and stub will suck the solder into place as shown.


    Now we are all done! Re-assemble the router the same way it was taken apart. You now have a WRT54GL that will not overheat! No more resets and random crashing any longer!

  2. crawdaddy

    crawdaddy Network Guru Member

    two things....this should have gone in the modding section, and does JB welkd work as a good heat transfer material?
  3. t4thfavor

    t4thfavor Network Guru Member

    Dunno, It is a semi metallic paste, but if you ever wanted to remove the heatsink it would not happen.

    I would probably recommend arctic silver adhesive paste. It is meant for the job.
  4. MangoMan

    MangoMan LI Guru Member

    JB weld is an excellent heat transfer material and can handle extreme heat! It also will never come off so if you want it to good luck. I added a resistor to the fan positive line as well with it's own heatsink to keep the fan running at half speed.
  5. jersully

    jersully LI Guru Member

    Sorry to resurrect this older thread, but I intend to do this soon. What other chips might benefit from a heat sink? The wireless chip, probably. And maybe the memory?
  6. Toastman

    Toastman Super Moderator Staff Member Member

    None of the chips in the WRT54GL benefit from heatsinks, unless you are seriously overclocking. Especially, please ignore any rumors you may have heard about the radio overheating and exploding ...
  7. macron

    macron Guest

    Its just me or the last 3 pictures are unavailable????
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