10 or 12 years ago I installed an electric fan on my 240Z to get that little extra HP to help out at the Autox and track day events. I scoured the boneyards and found that the 91-96 Escort fan would fit pretty well. So I cut the shroud down to get the best fit and wired it up:
I was pretty happy with it except it left about a third of the core uncovered and I'd thought about fabricating a full shroud. Last week the electric motor in the fan got too noisy to ignore so I pulled the radiator and fan and set about replacing the motor (had 2 on the shelf. The same motor is used in the Taurus and Sable fan that I use in my Scarab.) As I was doing this task I thought, what the heck, let's fab up that shroud I've been thinking about. So I grabbed some sheet aluminum and angle, set up my metal brake and set about this long delayed project. It wasn't nearly as difficult as I first imagined. Here's what I ended up with:
I bought some rubber flappers from SPAL like most modern fan shrouds have but instead of leaving a skinny vertical bar in the middle to keep the flapper from falling through I added some expanded metal I had laying around. I think that worked a lot better:
So the day after reinstalling the radiator and fan Val and I set off to the Early Bird in Pine for breakfast, her in her Murano, I in the 240. The new setup worked perfectly, temp staying right where it should be. Breakfast was great as usual. Afterward Val set off the check out some new eateries in Strawberry, I headed home. About 5 minutes out of Payson, I suddenly felt a hellavu vibration from the font end so I immediately headed for the shoulder and as I stopped I detected the sweet smell of hot coolant. ARRRRGH!
I unplugged the fan and restarted the engine and sure enough the vibration was gone. What the hell happened?
Called Val, she came and rescued me, we drove home and I hooked up the trailer and recovered the Z. After draining the rest of the coolant I pulled the radiator and found this:
My boneyard fan had had enough. And when it gave up part of its form, it poked two holes in the radiator:
So, at this point I'm faced with either taking the radiator to the valley for repair (for the 3rd time since owning the car since 1978) and trying to find another fan blade or failing that an entire new fan and shroud that I would have to cut to fit again.... or finally upgrading to that shiny new aluminum unit with dual fans. After searching online I found Champion offered a very nice 3 row with dual fans for ~ $475. A little more searching showed the same setup at Ledfoot Racing for $345, shipping included. Hmmm, about $100 more than sticking with my original radiator, no 2 trips to the valley, no cutting and trimming of a shroud...OK!
Upon receipt I found they'd sent me a fully polished setup for the price of a non-polished one. But they sent the wrong fans, 12" instead of the 11" to fit the shroud. A quick call and the right fans are on the way. The only other issue I've found is the mounting holes in the shroud don't quite line up with the radiator so I had to do some filing. I'm already wired for electric so I only need to change the plug on the harness to match the fans. And I'll need to drill holes and buy nuts/bolts to mount the fans and figure out where to mount the thermostat.
So hopefully I'll have everything installed shortly. While I'm disappointed I don't have the satisfaction of using the fruits of my labor, I'm also looking forward to seeing if the brand-spanking new setup is any better!