Soldering Fume Extractor ("FA400 plus")

I bought what I can only assume was a fake FA-400. Either way, it had a look only a mother could love (or a fanboy) and a sound that needed taming. First I installed silicone washers. This worked well, but I found the shape inconvenient and the performance not up to scratch. So this is a quick design that would work with any 120mm x 38mm AC fan. Or DC fan with a mod for power supply.

In this picture the solder is 25cm away from the fan and performance is excellent. The same fan in the new enclosure is miles is effective at almost twice the distance! This is really practical when working on keyboards, magnifying circuit boards and needing other soldering tools close at hand.

The fan suction power is much better than many of the 120mm varieties that are used. This solution can be oriented vertical or horizontal for convenience.

• AC Fan: (example 120mm x 38mm. fan is the standard 105mm screw hole to screw hole). My recommendation is you want a fan pulling similar to the specifications of the GDS time EC 12038 5000RPM  https://www.aliexpress.com/item/1005007401774479.html …. My understanding is that the 220V Hako original uses this Chiefly fan CC12038B220H. This may be it here https://www.aliexpress.us/item/3256803233051399.html 
• Switch: round 3 foot lamp https://www.aliexpress.com/item/4000789313176.html 
• Cord Strain relief: https://www.aliexpress.com/item/32869283574.html 
• Carbon Filter: https://www.aliexpress.com/item/1005001559548317.html 
• M4 Heat sets (7mm long x 7mm OD):  https://www.aliexpress.com/item/1005003582355741.html 
• M4 x 50mm https://www.aliexpress.com/item/32966157667.html 
• Washers https://www.aliexpress.com/item/1005001597115614.html 
• Wago https://www.aliexpress.com/item/1005003890170012.html 

Printing

Print the front face down with supports (you won't see the parts you need to clean up).

Print the rear face down. It shouldn't require supports, but you can use it as for the strain relief I did put a single sacrificial layer there, but you can do supports if your bridging is average.

Printed both with 2 walls, 20% infill.

Assembly

1. Clean up any supports. 
2. Do the wiring for the fan. The switch needs both neutral and active/hot wires. Put switch on active. Wago is required as neutral wire also needs to go to the fan.
3. Insert heat sets into rear.
4. Install one washer either side of the fan between bolt and case. Bottom of the rear will clip in before fully tightening. It is a fiddle, but a great noise free solution!
5. Carbon filter goes in last and should just securely sit in the front by itself.
6. Test first on a circuit with a safety switch.

Disclaimer: I won't diagram the wiring. If you don't know how to do this one, you probably shouldn't be fiddling with AC wiring. It is very straight forward, but should be done by a qualified person.