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[FurryNutz]

Ok, im not sure about the heat xfer compound and the affixing of the sink. I would try the heat tape that comes w those sinks first as test to make sure the sink will stock it the coposite sink. I suppose ur compound will work. We will want pics to see that though. Keep us posted.

[FurryNutz]

Just to keep things linked up on this similar issue, I bought a DIR-835 and here are my findings:
http://forums.dlink.com/index.php?topic=56166.0

[Syaoran]

Okay.  I got the heatsinks today and took the time to slap them on the same points that are shown  previously in this thread.  Keep in mind that I am using a DIR-857 (pictured) and the heatsinks I could round up are black but still made of aluminum.  I chose to use Arctic Silver MX4 for a couple of reasons.  It's a non-conductive thermal paste (not adhesive) with enough sticking power to hold them in place but also makes them fairly easy to remove and to clean off the compound as well. 






Please excuse the crappy camera on my Nexus 5 for the quality of the pictures. 

[FurryNutz]

Awesome pics man. Thanks for sharing.

I think the sink closest to the SD card hold will probably have to be removed as the routers cover will probably not fit, unless you leave the cover off entirely. 

Hope the testing will result in better operation. 

Keep us posted.

[Syaoran]

Awesome pics man. Thanks for sharing.

I think the sink closest to the SD card hold will probably have to be removed as the routers cover will probably not fit, unless you leave the cover off entirely. 

Hope the testing will result in better operation. 

Keep us posted.

I've had no issues getting the cover on.  I haven't put the screws back in it yet but will after a couple days of testing. 

[FurryNutz]

Ok, sounds good. Hope it works better...Keep us posted. 

[Syaoran]

A couple of things to note so far.  Whatever is under the diamond head spreader seems to be the hottest thing I can specifically identify in my unit.  Even with the heatsink on it and the Arctic Silver inbetween to help it transfer heat.  That heatsink (the one I've put on it) still hits 46C fairly easily.  The upper (towards the back of the unit) that I also put the heatsink on is hitting 41C also.  I remember getting temperatures in th4e mid-50's C before.  I haven't stressed it out a lot yet but these two spots, even with added cooling, need more to dissipate the type of heat both of those parts are generating.  The one closest to the front has been topping out at 36C so far.  I would say that is still on the warm side for not being fuly stressed. 

I have noticed that the bottom of the unit doesn't seem to be as hot but I am running with the top off currently.  This makes me wonder if a part of the heat issue with these routers is not enough ventilation on the top that is forcing that heat down and out the bottom and heating up the bottom of the router as well.  This is definitely a classic example of poor design coupled with a poor decision to be cheap on the cooling solution in my opinion. 

Expect more as I hammer this router over the weekend. 

[FurryNutz]

How is your router placed? What kind of materials are around it? Any metal?
Aren't you in a WiFi congested area?

What devices do you have connected to it? Wired and Wireless?

Hate to ask, however can you post C and F values please?

[Syaoran]

How is your router placed? What kind of materials are around it? Any metal?
Aren't you in a WiFi congested area?

What devices do you have connected to it? Wired and Wireless?

Hate to ask, however can you post C and F values please?

Nothing connected to wired other than my fiber modem but yeah, I have major congestion issues here.  One positive note, the Arctic Silver is doing a fantastic job in making sure that heat gets transferred to the heatsinks.  It's currently sitting on my hardwood floor away from everything without the plastic cover on the top.  The only things connected over wireless right now is my laptop using 5GHz N and my Wii-U on 2.4GHz N. 

[FurryNutz]

Do a couple of tests, Shut off the 2.4Ghz radio and leave the 5Ghz radio going. Then swap radios. Then turn OFF both radios and test temp at each stage.

Please report temps here...

[Syaoran]

Regardless of which is in use, I am finding the temperatures to be consistent. 

2.4GHz (5GHz off)

46.9C is the righest on the diamond.
36C is the highest on the heatsink closest to the back of the unit.
44C is the highest on the heatsink closest to the front of the unit.

5GHz (2.4GHz off)

Tempers were pretty much the same after the unit was turned off for an hour before checking the temperatures after 20 minutes of average use (single stream watching Netflix on N).  This was the same used for my testing on 5GHz. 

Point of note: If you look at the two heatsinks I have placed on the board and follow them over to where a connector from the side connects to the PCB.  The PCB around that connector tops out at 42.3C.  Whatever is under that point on the back side clearly isn't being cooled enough but there is no way to adequately cool it without creating a whole new hosing for the router. 

[FurryNutz]

Ok, So here seeing avg temps around 110F-115F.

What are the temps if you turn off Both Radios, 2.4Ghz and 5Ghz?

Is there any place besides this location you can take this router too to test this? Family or Friends and do the same temp tests? I'm curious if your WiFi congested area is having an impact on the WiFi, depending on your temp results of both radios being turned OFF.

[Syaoran]

Actually going to tackle that this afternoon as I'm just heading out for a few hours. 

[FurryNutz]

 
Also do you have access to a laptop cooler fan by chance?

[Syaoran]

With both radios off under the same cirumstances at the other, just wired.  The temps aren't much different at all.  

45.7C is the righest on the diamond.
35.3C is the highest on the heatsink closest to the back of the unit.
43.6C is the highest on the heatsink closest to the front of the unit.

I do have a laptop cooler but it's not really small enough to benefit the router.  Honestly, the best solution for cooling this router is copper heatsinks with a heatpipe and thicker, better thermal compound used, better ventilation, and active cooling.  I realize I may come off as a bit anti-D-Link with what I'm about to say but they clearly failed to make a respectable product here with both models.  Both the design and engineering teams behind this product along with the person who signed off to put it into production need to be fired!