geonc
SPIDER BAIT
This article shows how I converted electric fans from a '96 windstar to work on my OBS.
The actual modifications to the factory shroud and accompanying mods to the windstar fan assembly while direct to my '96PSD should be easily adaptable to both OBS IDI and brick/slantnose IDI trucks as well.
I was able to find at the local u-pull it yard the complete electric fan assembly from a '96 windstar with the 3.8 V6...the 3.8 has the largest fans so that is what I chose.
Also the Windstar assembly is the closest match in both height and width.
I also chose to retain the Ford factory shroud for a couple reasons…1- I can retain the lower tab mounts and the upper bolts
2- the lower radiator hose/bypass hose bracket is also retained there by eliminating the need to fabricate a way to mount the windsatr shroud and fabricate some sort of lower hose support.
The entire job cost me less than $100 and in real time {because I worked on it hit and miss} can be completed in a weekend.
parts list....from the bone yard...
complete electric fan assembly from a '96 Windstar van {don't forget the plugs!
Locate a second salvageable van and at least get the large fan motor--flatter of the two
from the parts house...
2-30 amp Bosch style relays
2-heavy duty fuse holders and 30 amp fuses
dash mounted switch of your choice
12' of 12 ga wire
10'of 16 ga wire
solder/heat shrink and split loom
misc crimp connectors for relays and battery connection
misc parts..
fiberglass matt and resin/hardener, 4.5" grinder discs, 1' of punch bar available at Lowes,HD etc...
tools...
jig saw, grinder/sander, basic hand tools.
This pic shows what IMVHO is the best and cleanest way to cut the shroud..thin 5.5" metal cut off wheels on a grinder...beats a sawzall hands down!
Begin by draining about a couple gallons {max} of coolant as it is nessecary to remove the top radiator hose to remove shroud/fan assy.
Also remember to un-bolt the lower radiator hose support.
REMEMBER---RIGHT hand threads on fan clutch!
Toss fan/clutch and let's get down to business!
The reason I chose to modify the Windstar fan shroud to accept another flatter motor and graft to my shroud as opposed to using the smaller but more prominent motor is clearly evident in this pic...
Doing so also eliminates the need to fab up some sort of brackets to mount the Windstar shroud to the side of the radiator tabs.
Now, with your truck shroud face up, place the Windstar shroud on top and you will see the areas to be removed in order for the two to match up as cleanly as possible.....
Also now is a good time to clip flush the Windstar shroud mount tabs!
This pic shows the end result and the following pic shows the test fit...
Here is the way I kept everything as true as possible...
Here it just needs a little clean up....
Everything in plane!
First layer of fiberglass that will have 2 more layers---mebee a bit over done but I like doing things once! Second pic shows ready for fans....
Here is some punch bar I added for rigidity...a couple inches in each corner along with 3 layers of fiberglass makes a strong connection!
That is it for the actual shroud modification....sand to your level of acceptance and give a good coat or two of black spray paint!
Adapting the motors and modifying the small fan to fit the larger motor is next!
The actual modifications to the factory shroud and accompanying mods to the windstar fan assembly while direct to my '96PSD should be easily adaptable to both OBS IDI and brick/slantnose IDI trucks as well.
I was able to find at the local u-pull it yard the complete electric fan assembly from a '96 windstar with the 3.8 V6...the 3.8 has the largest fans so that is what I chose.
Also the Windstar assembly is the closest match in both height and width.
I also chose to retain the Ford factory shroud for a couple reasons…1- I can retain the lower tab mounts and the upper bolts
2- the lower radiator hose/bypass hose bracket is also retained there by eliminating the need to fabricate a way to mount the windsatr shroud and fabricate some sort of lower hose support.
The entire job cost me less than $100 and in real time {because I worked on it hit and miss} can be completed in a weekend.
parts list....from the bone yard...
complete electric fan assembly from a '96 Windstar van {don't forget the plugs!
Locate a second salvageable van and at least get the large fan motor--flatter of the two
from the parts house...
2-30 amp Bosch style relays
2-heavy duty fuse holders and 30 amp fuses
dash mounted switch of your choice
12' of 12 ga wire
10'of 16 ga wire
solder/heat shrink and split loom
misc crimp connectors for relays and battery connection
misc parts..
fiberglass matt and resin/hardener, 4.5" grinder discs, 1' of punch bar available at Lowes,HD etc...
tools...
jig saw, grinder/sander, basic hand tools.
This pic shows what IMVHO is the best and cleanest way to cut the shroud..thin 5.5" metal cut off wheels on a grinder...beats a sawzall hands down!
You must be registered for see images attach
Begin by draining about a couple gallons {max} of coolant as it is nessecary to remove the top radiator hose to remove shroud/fan assy.
Also remember to un-bolt the lower radiator hose support.
REMEMBER---RIGHT hand threads on fan clutch!
Toss fan/clutch and let's get down to business!
The reason I chose to modify the Windstar fan shroud to accept another flatter motor and graft to my shroud as opposed to using the smaller but more prominent motor is clearly evident in this pic...
You must be registered for see images attach
Doing so also eliminates the need to fab up some sort of brackets to mount the Windstar shroud to the side of the radiator tabs.
Now, with your truck shroud face up, place the Windstar shroud on top and you will see the areas to be removed in order for the two to match up as cleanly as possible.....
Also now is a good time to clip flush the Windstar shroud mount tabs!
You must be registered for see images attach
This pic shows the end result and the following pic shows the test fit...
You must be registered for see images attach
You must be registered for see images attach
Here is the way I kept everything as true as possible...
You must be registered for see images attach
Here it just needs a little clean up....
You must be registered for see images attach
Everything in plane!
You must be registered for see images attach
First layer of fiberglass that will have 2 more layers---mebee a bit over done but I like doing things once! Second pic shows ready for fans....
You must be registered for see images attach
You must be registered for see images attach
Here is some punch bar I added for rigidity...a couple inches in each corner along with 3 layers of fiberglass makes a strong connection!
You must be registered for see images attach
You must be registered for see images attach
That is it for the actual shroud modification....sand to your level of acceptance and give a good coat or two of black spray paint!
Adapting the motors and modifying the small fan to fit the larger motor is next!
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