pma4x4
AKA Yankeeroad
More column pics
Last edited:
CK5
Register an account today to become a member! Once signed in, you'll be able to participate on this site by adding your own topics and posts, as well as connect with other members.
Project MULE - Expedition build on a 1991 1500 4x4 Suburban
- Thread starter pma4x4
- Start date
pma4x4
AKA Yankeeroad
Ford Windstar fan upgrade, Like a glove!
My radiator is the 28-1/4" wide core. The aluminum angle is 3/4"x2" architectural. that is important is it need to be architectural so it has square edges for more defined room. The hardware was 10-24x2" for the flange mounting with 1.2" steel tubes for spacers and locknuts and washers. I used 10-24x1/4" screws and locknuts to mount the fan to the angle metal. The drill bit i used was a brand new Irwin 3/16" self centereing bit. The holes thru the angle were 1/4" from the inside corner out.
People exaggerate these Windstar fans. I grabbed a DC clamp meter and did 10 startups and run averages on both fans. a regular 40 amp bosch style relay and a 25-30 amp mini fuse will work just fine. as long as you run like under 4 ft you can use 12ga wire for the power.
The new dorman fan is only $100 new via amazon https://amzn.to/2rWp5jX
My radiator is the 28-1/4" wide core. The aluminum angle is 3/4"x2" architectural. that is important is it need to be architectural so it has square edges for more defined room. The hardware was 10-24x2" for the flange mounting with 1.2" steel tubes for spacers and locknuts and washers. I used 10-24x1/4" screws and locknuts to mount the fan to the angle metal. The drill bit i used was a brand new Irwin 3/16" self centereing bit. The holes thru the angle were 1/4" from the inside corner out.
People exaggerate these Windstar fans. I grabbed a DC clamp meter and did 10 startups and run averages on both fans. a regular 40 amp bosch style relay and a 25-30 amp mini fuse will work just fine. as long as you run like under 4 ft you can use 12ga wire for the power.
The new dorman fan is only $100 new via amazon https://amzn.to/2rWp5jX
pma4x4
AKA Yankeeroad
More Fan upgrade pics
pma4x4
AKA Yankeeroad
I originally got two thermal controlled relay kits from amazon. in short.... DON'T. both sensors have stopped working. For now I have the fans wired to come on with ignition. I am still trying to research a good thermal switch around the 200* temp that will fit and work. I had to go round and round with amazon for warranty/return. I had to explain to them that the wires are cut to length and the crimps have been used. Also I will loose about $20 out of pocket just in coolant when I pull the thermal switches. In end they refunded me the full amounts on both kits. I am not proud of this wiring on these fans. I did it kinda quick so I could get the truck up and going again. I do plan to rewire the entire accessory harness I have created over the years and hopeful improve on it and get it cleaned up some more.
The awesome part of this is when the fans are running my live scan app shows the ECM reading right around 204* the whole time I'm running. Now we will see how this works come a mid Arizona Summer with the AC on and traffic. Results on power gains is actually noticeable. the engine will climb in RPMs quicker and gets up to highways speed easy. Because I am not int he throttle as much I gained a few inches in vacuum so it stays in lockup much easier which translates to mpg gains as well.
The awesome part of this is when the fans are running my live scan app shows the ECM reading right around 204* the whole time I'm running. Now we will see how this works come a mid Arizona Summer with the AC on and traffic. Results on power gains is actually noticeable. the engine will climb in RPMs quicker and gets up to highways speed easy. Because I am not int he throttle as much I gained a few inches in vacuum so it stays in lockup much easier which translates to mpg gains as well.
Horton offers some really nice temp switches for semi truck applications. Not cheap at all. Like when I searched them they are around $80-90 but can probably be had for less. http://catalog.hortonww.com/catalog/pneu_thermal_switch.asp Lots of options.
pma4x4
AKA Yankeeroad
Ill have to check them out. Thanks!
pma4x4
AKA Yankeeroad
change things up a bit. not going to be using the Mule for cross country much anymore so the swing outs are up for grabs
Custom Dual swing outs. These came of my barn door 91. I used to sell custom bumper and stuff and have changed gears and no longer need these on my truck. they served us well with a few trips across the US back country. Together they weigh 98lbs. You can open the pass side to gain access with the single barn door if need be. Will clear tailgate design as well. Comes in powder coat wrinkle black.
Designed to hold
Spare tire with 6x5.5 pattern
High lift
axe
pick axe
short shovel
10-20lb CO2 tank (depending in diameter of tank)
5lb Propane tank (included)
(2) genuine Nato Jerry cans (harbor freight ones should work)
pop lock pins to hold the swing outs open.
Spot to mount your license plate and light it up.
greasable common bearings for the spindle
Comes with brand new machined spindles and sleeves. NOT TRAILER SPINDLES.
Also comes with larg lock to secure Hi-Lift
Swing outs only NO BUMPER
$600 for the set. Meeting somewhere in Arizona is possible IF you pay in full via Payal, MO or CC.
Locate in Apache Junction, AZ
Custom Dual swing outs. These came of my barn door 91. I used to sell custom bumper and stuff and have changed gears and no longer need these on my truck. they served us well with a few trips across the US back country. Together they weigh 98lbs. You can open the pass side to gain access with the single barn door if need be. Will clear tailgate design as well. Comes in powder coat wrinkle black.
Designed to hold
Spare tire with 6x5.5 pattern
High lift
axe
pick axe
short shovel
10-20lb CO2 tank (depending in diameter of tank)
5lb Propane tank (included)
(2) genuine Nato Jerry cans (harbor freight ones should work)
pop lock pins to hold the swing outs open.
Spot to mount your license plate and light it up.
greasable common bearings for the spindle
Comes with brand new machined spindles and sleeves. NOT TRAILER SPINDLES.
Also comes with larg lock to secure Hi-Lift
Swing outs only NO BUMPER
$600 for the set. Meeting somewhere in Arizona is possible IF you pay in full via Payal, MO or CC.
Locate in Apache Junction, AZ
Is there a chance you have the plans for your swing outs available?
pma4x4
AKA Yankeeroad
I have some dimensions for the bumper but jack squat for the swingouts. It was kind of a build them as I went to see what fit where.
Hey Rob, are those temp senders grounding out ok in the spacer? I was looking into the spacer and it seems the threads are anodized...maybe it’s not cutting through to the aluminum and/or grounding through the bolts? Otherwise does the spacer play nice with the rad hose placement?I originally got two thermal controlled relay kits from amazon. in short.... DON'T. both sensors have stopped working. For now I have the fans wired to come on with ignition. I am still trying to research a good thermal switch around the 200* temp that will fit and work. I had to go round and round with amazon for warranty/return. I had to explain to them that the wires are cut to length and the crimps have been used. Also I will loose about $20 out of pocket just in coolant when I pull the thermal switches. In end they refunded me the full amounts on both kits. I am not proud of this wiring on these fans. I did it kinda quick so I could get the truck up and going again. I do plan to rewire the entire accessory harness I have created over the years and hopeful improve on it and get it cleaned up some more.
The awesome part of this is when the fans are running my live scan app shows the ECM reading right around 204* the whole time I'm running. Now we will see how this works come a mid Arizona Summer with the AC on and traffic. Results on power gains is actually noticeable. the engine will climb in RPMs quicker and gets up to highways speed easy. Because I am not int he throttle as much I gained a few inches in vacuum so it stays in lockup much easier which translates to mpg gains as well.
pma4x4
AKA Yankeeroad
They were an epic fail. Had Amazon refund the full amount on both of those. Yeah had grounding issue then they both just stopped working all together. I have the fan signal temporarily wired to a ignition source but I found the controller I need. its does two fans and uses a GM temp sensor and not a thermal switch. Just need to get around to ordering it. You still need the relays and wiring. this is just the controller unit using a regular temp sensor.
https://www.ebay.com/itm/HPC-Electr...h=item4b01a358cc:g:2TwAAOxy7MtRvmqx:rk:1:pf:0
https://www.ebay.com/itm/HPC-Electr...h=item4b01a358cc:g:2TwAAOxy7MtRvmqx:rk:1:pf:0
That thing looks cool. I have a temp switch that got “loose” over the years and another new one I plan to try. If it doesn’t work I’ll have to look into that thing.
pma4x4
AKA Yankeeroad
After a bunch of horse trading and swapping and parting stuff out I ended up with a 2000 6.0 truck motor. I got the HPtuners and did the VATS delete and did a test run. All in all Im only into this project for just the cost of the HPtuners and the credits for the ECM unlock.
We are hoping to swap this in before we move this fall.
We are hoping to swap this in before we move this fall.
Hey Rob, it's been a year! How are things going for you and the Mule?
