I remember about a year ago when a few posted a simple guide (or a link to it) with pics on modding the original X-Connect 500W PSU fans so that they always will run at 12v and bypass the built in thermal controller. I can't find it, can anyone help me out?

Just solder tham directly to the 12v rail (Yellow and black) but this doesn't work very well, as the fans are still real slow at "full" speeds. Just get faster fans and stick them in

So let me make sure that I understand what you are suggesting. Leave teh conections alone, and buy new fans to replace the current ones. Do you have a suggestion on fans? Are they 80mmx25mm?

No...just cut the fan wires from wherever they go and resolder them directly to the 12v rail and ground...I did this on mine and it definitely turns it into a whole 'nother PSU. My 12v is now steady around 12.0x load and idle, whereas before it would be all over from 12.1x to 11.8x.

Hmmm, I didn't notice that much of a difference on mine, I ended up buying two regular 80x80x25mm fans and sticking them in, and ran the connections outside the PSU through a drilled hole to a molex connector, IMO, easier and the better thing to do

but yeah, you can cut the connections, and solder them to the 12v and ground rails (Yellow and black) and see if that helps any

I assume yellow is hot and black is ground?

Yellow is VERY hot, I wouldn't recommend touching it without gloves...

Can anybody find a link to pics? I can't anymore.

dude... it's silly easy... I guess i'm pulling out my x-connect then out of my server...........................................

You dont really need a picture, here let me walk through it from discharging the power supply.

With your PSu removed, plug it into the wall, attach a few fans onto it, turn it on by shorting the green pin and ANY black pin on the motherboard power connector. Flip the switch on the back to turn it on, then pull it from the wall, this will allow the power supply to drain.

Then, pop it open, your fan is connected to the PCB via either a small molex or solderd directly to it, the wires you see are red and black Id assume. Snip the wires, and heatshrink the ends to prevent short circuit.

Then, strip the fan wires.

Now you have a few choices here, you can power it in 12V, 7V or 5V. I am assuming you want 12V SOoo..

Follow the leads from the modular plug down to the PCB, you are looking for yellow wires. Solder the red wire from the fan to any of these and the black to the end of any other black wire and there you have it, the fan now runs 12V continuously.