Router Cooling Mod
I bought a D-Link G604T ADSL wi-fi router to share our ADSL connection between my computer and my girlfriend's. Unfortunately I didn't discover beforehand that this model has a reputation for overheating and locking up, and the moderate warmth of our airing cupboard was too much for it, causing it to lock up after a few hours.
I had a spare cooling fan lying around, and noticed that the router was powered by 12V. I took the router apart - the case is held together by two bolts, and the circuit board is held in place by mounting lugs and by the aerial connection, which is fixed to the case with nuts. Once these were removed the whole circuit board could be lifted out and examined. The power connections were easy to find, and a quick bit of experimentation showed which way round to connect the cooling fan.
The fan leads are soldered onto the back of the circuit board.
So I used a jigsaw to cut a fan-sized hole in the side of the plastic case and drilled 4 mounting holes. The fan leads were soldered directly on to the back of the circuit board, where the power rails from the connector are joined on. Then I screwed the fan to the case (from the inside, so the ends of the screws weren't protruding down towards the components inside) and replaced the aerial connector and the cover.
The big fan hanging off the side isn't exactly pretty, but it's very effective!
Powering up, everything still worked! After leaving the router running for some time, the circuitry felt much cooler than before. I replaced the router in the airing cupboard, and it has been happy ever since.
The router is now happy and cool in the airing cupboard. For good measure, I put a spare ferrite choke on the lead from the mains adapter.
If you have been inspired to do something similar to your G604T, please bear in mind that this will certainly void your warranty. Although the additional cooling has solved the problems I experienced, YMMV and I take no responsibility whatsoever for any problems you cause yourself or anyone else by modifying your hardware.