do you have a write up somewhere? i have been wondering about the same thing. i know a lot of guys over on FullSizeBronco use electric fans, but haven't been able to find much here. how much air do your fans move?
there really isn't all that much to it.its a simple follow your instincts fun easy mod.
remove your stock energy robber and once you fit the assembly down in,you'll look to see if something needs to be shaved.like the upper lip i shaved down so the fans could set closer to the rad for more clearance.the 3 corners just required pilot holes to be drilled,and then some self tappers.
i then used a bolt/ multi nut setup for the upper pass side due to it having an outset mount here.
then its just a matter of getting what you want to make them spin.
the ford windstar fans have approx 4400 cfm combined.i find they hardly need to come on,and when they do,its usually low or medium.if ever on high,it's for a very short duration.
i used the fk85 variable rate controller from here:
http://www.dccontrol.com/
i started with a normal relay based type that simply turned them on/off.the problem was the fans are just overkill on high,so i had to tone them down.
geonc's guide here was my inspiration.i just decided not to frig with the massive fan shroud because the e-fans are designed to work just fine in their own.the large stock one is so massive because the fan blade is.
if i was going to do it again,i probably would follow his advice on swapping out the larger motor for another short for easier/more room.shaving the shroud and being careful did work however as you can see.though,she's a tight fit.you could always spin the whole assembly and run it upside down.that would put the larger motor on the pass side.wouldn't hurt a thing.i decided to just see if it would fit,and it did,so i called it good.
8k lb empty truck.
Maine hilly terrain.-we have quick very,very steep hills.so your going up fast and getting it over with quickly before temps can hardly climb.
long drawn out large mountains,and towing heavy; your going to find much different results im sure.
100 degree temp days are few and far between.mainly 80-90's in summer.high sticky humidity.
i don't exceed the trucks towing capacity.im typically grossing 14-16k total max loaded up with wood/chips/towing chipper.
the fans work much more in the winter with the snow plow on,than summer heat working the truck by a large margin.
even if they are from a ...Chebby!
Holds the inrush and running load just fine! Now while mine are based on a Winstar setup..I did not see the need for using the variable speeds...only thing different is the need for auto engage at idle..or in the case of the OBS PSD triggered off the IVS on the loud pedal that fires a relay that fires another relay if the AC clutch is powered. Now the IVS is NC when above idle so no voltage is present till the IVS activates so it is nesc to use that 5th post on the Bosch relay or 87a or else you will be energizing the AC relay all the time......
