I designed this enclosure for an Arctic Air 80x80x25mm PC fan, so I could use it to help remove smoke and fumes when LASER cutting materials on my cheap Chinese CNC machine. The CNC has a 2020 aluminium extrusion frame, so initially I made a mounting to place it on that, but later adapted it for a simple enclosure. The enclosure mounting does a much better job of extracting fumes, but I've included both types of mounting here for you to choose from.
The fan case is designed to fit around the fan itself, being held together using long bolts through the holes in the corners. The box for a power socket and switch, as well as the side and bottom mounts, are then glued on. Also, the two 60mm hose connector rings need carefully gluing together so that the back of the fan enclosure fits into it and rotates. I used a plastic wrapped spiral-wire hose so I included small holes to allow it to be fixed in the ring with cable ties.
I designed the models to be printable on low end 3D printers, like the DaVinci Jr 1.0 I have, without too much support material. However, in case you'd like to change the design I've included the OpenSCAD file. Also, if you'd like to read my blog-post about this project please just follow the link below.