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Discussion Starter #1
Another Budget build.

Well, as I am putting the car back together after some front end modifications
I wasn't about to reinstall that big ass fan shroud ever again. I wanted to do
an electric fan setup back when I replaced the radiator last fall but didn't have
the time or money to do so. After reading several post here and other sites I found
that I wanted to do the Ford Focus dual fan setup over the other single units.

This setup will be run on two separate controls, one for each fan to be able to
eliminate total fan failure if in the event that one of the fans happen to short out
it won't take out both.

I bought a new Ford Focus fan on Ebay for, winning bid of $11.25 plus $20 shipping:partyon:


These fans can be bought for around $100 on Ebay at any time.

I started with making some brackets out of 1'' angle iron and 1'' square tube.



Then I sand blasted the frames and shot some spray on them and attached them to the shroud.



And then installed it in the car. The frames were made to set in the same
U-brackets that the radiator does, to simplify the setup.






I now have to wire up the fans but didn't have time today to get that done.

Does anybody know what the wattage or fuse size is for each of the focus fans are?
There is no info on the fans about their draw.

I will start out with 25amp fuses and 30amp relays and see if that will hold.


I will post some more latter after I finish the install.

Riggs.
 

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I wasn't about to reinstall that big ass fan shroud ever again.
:laughing: that was the main reason for my electric fan swap as well. What a PITA.

Looks like a good setup. Sorry I can't help you on the current draw, but for what it's worth I've been running a 30 amp fuse for low speed on the taurus fan and haven't had any issues yet.
 

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Very cool :thumbsup: I love all of the DIY budget build threads you've been doing lately.

Just a word of advice, if you are going to buy a "pre-made" fan controller, make sure you dont cheap out. I did the first time around, and it almost cost me my car. After that, I just made myself a simple setup using 2 hella 40amp relays, a painless temp switch, and some heavy duty in-line 25amp fuses.
 

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Discussion Starter #6
Wiring is all done.

First off for anybody doing there research and gathering their parts, I need to
remind others that you will have to up size your alternator to a larger size,
110 amp with AC, and you should be able to get away with with a 78 amp
if your not running AC. I have AC but I intend to eliminate it or just not run it for now.

After I test this set up, I hope to take some amp readings to see just how much
these fan draw, I have asked and searched and nobody knows.


I pulled my power from my starter/battery terminal using #10 (red) wire up to my
30 amp breakers, One wire to each.
(the taped up harness is from the previous owner, I'll tidy it up later)



Then from each breaker I ran one #12 (red) to the each relay as the supply power.



Then I ran the thermostat switches out to the front of the engine, On the
one in the intake this will be the ground path from the engine to the relay, and
on the other in the top of the water pump is a line in/line out switch. These switches
will turn the fans off and on at different temperatures, one slightly different
than the other.



Then I ran #12 from the switched side of the relay to a fuse at the fans
and picked up a #12 ground (black) from the alternator case and ran it to the fans directly.
From the fuses I finished off the circuit to the fans with more #12 wire.






Here is another look at the wiring diagram, This is basically what I done.



I hope to test the fans this weekend.

Riggs.
 

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I'm a little confused on the two switches. Are they both serving the same function, one for each fan? Or is one of them controlling both fans? Are they just simple temp switches with a particular setpoint at which they close to ground (through the threads)?
 

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It looks like he's going to use two of the diagrams he just posted. Each one will turn the fan on and off at his selected temps and they remain isolated from each other. The relays are cheap and easy to wire up. I bought the same fan , mounted it a little differently. I also picked up a CS144 from the junk yard off of a Cadillac STS I believe. I ran the Alternator wire right to the battery as oppose to the starter terminal and I'm using a terminal strip on the fender well only because I have to wire in my headlight motors as well.Cleaner that way for me anyways.
 

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It looks like he's going to use two of the diagrams he just posted. Each one will turn the fan on and off at his selected temps and they remain isolated from each other. The relays are cheap and easy to wire up. I bought the same fan , mounted it a little differently. I also picked up a CS144 from the junk yard off of a Cadillac STS I believe. I ran the Alternator wire right to the battery as oppose to the starter terminal and I'm using a terminal strip on the fender well only because I have to wire in my headlight motors as well.Cleaner that way for me anyways.
Can we see your set up ? ? I like that the fans are nice and neat..
 

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Here's the rad and fans. I made the support bracket this way so I can use some onesided tape weather stripping to seal the fan shroud to the rad close enough so the fans aren't touching the rad. Keep in mind also, do not box in your front right frame horn completely, it will hit the lower rad outlet. I have VBP control arms and I had to clearance the shroud on both sides a tiny bit on the outer side.



 

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Discussion Starter #13
Update,

The fans and controls work great. The dual fan setup is real quite, this
was a great budget build.

I brought the car up to temperature and made sure the fans were going
to come on and that every thing was working the way it should. Then
I pulled the relays to let the car come up past 200, then plugged the relays
back in and the temperature fell quick. Granted, this is not a 90 degree day but I
think it will be just fine in extreme heat conditions.

You can't beat the cost that I have in this, Fans, controls, Brass reducers
and wire, I only have about $140 in it, not bad.

Riggs.
 

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I really like this set up.. Any way you can post a detailed list of parts and any other thing you may have needed for the install.. I have a few fans on ebay already that im scouting out and would like to do this conversion.. Also maybe some dimensions of the brackets yo mad to connect the fans ... Thanks for the info gotta love the DC family..



Update,

The fans and controls work great. The dual fan setup is real quite, this
was a great budget build.

I brought the car up to temperature and made sure the fans were going
to come on and that every thing was working the way it should. Then
I pulled the relays to let the car come up past 200, then plugged the relays
back in and the temperature fell quick. Granted, this is not a 90 degree day but I
think it will be just fine in extreme heat conditions.

You can't beat the cost that I have in this, Fans, controls, Brass reducers
and wire, I only have about $140 in it, not bad.

Riggs.
 

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Discussion Starter #18
ptroxx,
I didn't make any template's and the easiest way since the cooling system
is being pulled apart would be pull out the radiator and mock up the new fan,
but test fit it before you settle on you setup, once you have the fans setting
in the car the way you want it, finish the brackets. The one thing you will have
to look out for is the location of the upper control arm bushings.
You might even decide that the Ford Torus fan would be a better setup, do to
space, or the lack of.

As for the rest of the stuff, you can buy the relay set up from summit, jegs, or
any other auto parts store.

I did buy some extra #10 and #12 wire,some #10 but crimps, some wire loom,
and some different size brass plugs to fit the thermo switch's into the front
of the engine.

If you don't mind having the car apart for a while, take your time and put together
something that fits well into you engine bay.


Riggs.
 

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Cool, thanks for the info.. I was looking at the other ford fans too.. kinda like them too.. my plan is to do it for a next winter project but start collecting things now.. I do a lot of cruises and dont want to have the car down to long as the good weather is coming .. I dont have a welder so it will take a while to do the brackets, but i have a great welding shop to go to so not to worried .. thansk for the heads up on the other parts..

Now I do have another question... OK so the connectors from the fans.. ? ? where did you get those.

Thanks again man..

ptroxx,
I didn't make any template's and the easiest way since the cooling system
is being pulled apart would be pull out the radiator and mock up the new fan,
but test fit it before you settle on you setup, once you have the fans setting
in the car the way you want it, finish the brackets. The one thing you will have
to look out for is the location of the upper control arm bushings.
You might even decide that the Ford Torus fan would be a better setup, do to
space, or the lack of.

As for the rest of the stuff, you can buy the relay set up from summit, jegs, or
any other auto parts store.

I did buy some extra #10 and #12 wire,some #10 but crimps, some wire loom,
and some different size brass plugs to fit the thermo switch's into the front
of the engine.

If you don't mind having the car apart for a while, take your time and put together
something that fits well into you engine bay.


Riggs.
 

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Discussion Starter #20
ptroxx,
I have seen a few guys make up their fan brackets/shrouds from flat
aluminum and rivets, so no welding required.
As far as the wire connectors at the fan, those come with these fans
in a pre made harness that I took apart to rework for my setup.

Riggs.
 
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