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Electric Fans

As soon as I figure out what to do with the slack for the probe I'll move it back to the inlet side. I had it there originally, but I cant shorten the probe wire. So whenI clean up that side of the engine bay, I'll find a place for the excess that wont get in the way or snagged if I ever work back there again. As for the shroud, let me see how it does first, but I end up needing one, where would I go to find a generic setup. I'm not good at fabricating plastic, and I dont have access to any brakes or benders for sheetmetal.
 
I used straight steel for mounting.

If you look at where the factory shroud bolts up, you'll see that there are at least two holes along the lower portion of where the radiator mounts in the sheet metal lip. I bolted the steel "straps" into each of those, and then to the top radiator mounts where the shroud bolted. I used round steel cross pieces to hold the shroud against the vertical steel straps. Had my dad weld it together. Not complex at all, works good.

The deal with the shroud for electric fans I believe was already mentioned...if you put the fan against the radiator, the radiator fins actually restrict airflow, so you may be working the fan harder, with less efficiency, than if its mounted an inch or so AWAY from the radiator, with shrouding that forces air to move across the entire radiator, but still through the fan...the velocity through the radiator will be reduced overall, but the area that the air is pulled through will increase.
 
I have some flat steel that has predrilled holes in it. Rigid enough to use in front of the fan blades, but bendable enough to contour as I need it to. That takes care of the bracketry. I understand why I would need a shroud, but the stock one was junked when the new engine went in due to excessive cracking. I want to find a generic kit of if someone know how to make a DIY with common materials that doesnt require alot of fabrication.
 
I suspect this is one reason the windstar swap is so popular...everything is essentially done for these trucks. I wish I would have known about it before doing all of mine. :)

Stock shroud IMO wouldn't work well for the electric fan. A real "thin" (protruding into the engine bay minimally) shroud would be my preference. I still believe that all shrouds should have "flappers" on them that open when the vehicle is moving forward. Helps to allow more air through the radiator.
 
Flappers, eh? I could build the framework, and I know what materials I could use, but where to find them could be tricky. Something that would withstand the heat in the engine compartment, but light enough to close on suction from the fan at a standstill. Or something with a VERY light spring assembly on it. Does anyone know of a place that would sell sheets of ABS plastic? I'll check online, but i want to be able to feel it before I order soemthing that isnt going to work. PVC plastic might be more available, but I dont think it handle the constant exposure to the temps. We use some poly-ethelene stuff for comm cables that handles heat and sun exposure pretty well, but it wouldnt be rigid enough nor would I find it in flat sheets. HVAC sheetmetal could work, but I dont have a brake or the proper cutting stuff to work sheetmetal. Nuts, I'm stumped.
 
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