Originally Posted by Giallocool
Wouldn't it be easier to just replace the two existing internal fans with better quieter ones?
No, the loud fan is the fourth fan, which is a blower fan not a rotary one, it's in the middle underneath the circuit board and you can't see it in that picture.
Google the service manual and you will see it. I've taken the projector 100% apart and put it back together to clean it because it was overheating and had dust blobs, it's definitely the blower fan causing all that noise.
The only way to fit a quieter blower fan to cool the lamp down, is get a quieter and therefore bigger one. But then it won't fit. So, basically, choices are rather limited. I checked on alibaba for quiet blower fans but didn't find a suitable drop in replacement. There may be one, but IMO it's better to just build a small custom enclosure and replace the blower fan with a bigger unit that is rated for quiet operation.
Or, if you don't mind hacking the plastic, simply drill a big enough hole in the base of the projector to stick an air hose in and then you can have your cake and eat it too. Or just open up the lamp lid, tape an eraser head to hold the release button down, (so the projector thinks the lid is still closed. if the button isn't pressed, the power doesn't turn on). Then you can just stick a blower fan right there and do it. But then it gets tricky, because there is a heat sensor that monitors for overheating to turn the lamp off. This part you definitely want to keep. And the blower fan input port needs to be connected to the outboard blower fan, to modulate the fan speed otherwise the projector might also not turn on. Although this part I'm not sure of. In theory you could get an external blower to keep the lamp cool but then dust would have an easier time getting in. On the other hand, the side vents aren't dust proof which is IMO pretty dumb. First step should be to get some dust filters in there.
Yeah, screw the hush box. Fix the problem at its source : unplug the blower fan and plug in a bigger, quieter one and have it rigged up from the lid to blow cool air in. Probably the best plan, actually, is to take off the left plastic port, and run a hose in the the underbelly where the current blower fan lives, so that the air can flow into the lamp's input port. That way there is no permanent damage to the projector but it would be better to just make a small hole in either the left side or the back panel and run the hose in there. Maybe the back would be the best, like right above the power plug port.
Or, drill a hole in the base and stick the blower right there, and add a couple sleeves to route the air flow from the external blower right into the lamp enclosure.