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Old 04-08-2008, 12:23 AM   #1 (permalink)
Franko914
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Dual Electric Cooling Fans Installed

Hello All,

I finally completed my dual electric cooling fan installation. I used two (2) Bosch (manufactured for Volvo p/n 8649522) fans obtained from fleaBay. Each fan has an all-enclosed plastic shroud (see note later on this important feature), silent S-blades, a powerful motor that draws 18 amps and a 3,000+ CFM rating.

Pics #1 and #2 show the stock fan shrouds (upper and lower) removed from engine compartment. The first shows the clearance of the fan clutch from the radiator. The second shows a rear perspective of the radiator – if you zoom in to the bottom of the radiator, you can just about see the 1/4" gap, about 3/4" deep, between the radiator and the lip of the radiator support. This will be used to anchor the base of the dual electric fan assembly

Attached Images
File Type: jpg 01_StockFan.jpg (56.8 KB, 1017 views)
File Type: jpg 02_StockFan.jpg (48.7 KB, 914 views)
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98 4WD Tahoe 6.5TD 215k Z-71 LT; Remote Mount Dual Reusable SS Oil Filter; Racor 10micron Fuel Filter; K&N Air Filter w/10' Oiled Cotton Gauze Prefilter; SS Diesel Supply FSD w/Cooler; Spare FSD on Same Cooler; HD Hellwig Sway Bars Front/Rear; OPS Bypassed for Lift Pump; 230 Amp Iraggi Alternator; RunCool Dual SS Hood Louvres; 285x75x16 Chapparal A/P; Mechanical Turbo Boost Gage; IP replaced at 100k and 200k miles; Shrouded Dual Electric Cooling Fans @6,000+CFM total; Rear-Facing 12 Gauge Remington 870 for TailGaters.

Soon: "F" Uppper/Lower Intakes; Vacuum+Pyrometer/EGT+Differential Oil Pressure+Differential Fuel Pressure Gages; Extended Glow Controller; High Idle Switch; MAP Boost Fooler; Two-Stage Water Mist Injection; Hitch Mount Fold Down Spare Tire Carrier; Electric Fans for Hood Louvers.

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Old 04-08-2008, 12:27 AM   #2 (permalink)
Franko914
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Pics #3, #4 and #5 show the plastic shrouds cut to fit the height of the radiator, which measures 20” high. The cut pieces are further trimmed and will be reattached to the plastic shroud to maintain the all-enclosed feature. That’s a metal cutting disc on the angle grinder.

Attached Images
File Type: jpg 03_CoolingFans-Rear-TopsCut.jpg (125.7 KB, 571 views)
File Type: jpg 04_CoolingFans-Front-TopsCut.jpg (101.5 KB, 441 views)
File Type: jpg 05_CoolingFanShroud-Trim.jpg (49.9 KB, 495 views)
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Mad Franko
98 4WD Tahoe 6.5TD 215k Z-71 LT; Remote Mount Dual Reusable SS Oil Filter; Racor 10micron Fuel Filter; K&N Air Filter w/10' Oiled Cotton Gauze Prefilter; SS Diesel Supply FSD w/Cooler; Spare FSD on Same Cooler; HD Hellwig Sway Bars Front/Rear; OPS Bypassed for Lift Pump; 230 Amp Iraggi Alternator; RunCool Dual SS Hood Louvres; 285x75x16 Chapparal A/P; Mechanical Turbo Boost Gage; IP replaced at 100k and 200k miles; Shrouded Dual Electric Cooling Fans @6,000+CFM total; Rear-Facing 12 Gauge Remington 870 for TailGaters.

Soon: "F" Uppper/Lower Intakes; Vacuum+Pyrometer/EGT+Differential Oil Pressure+Differential Fuel Pressure Gages; Extended Glow Controller; High Idle Switch; MAP Boost Fooler; Two-Stage Water Mist Injection; Hitch Mount Fold Down Spare Tire Carrier; Electric Fans for Hood Louvers.

Enforce the First Gun Law: The Second Amendment
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Old 04-08-2008, 12:29 AM   #3 (permalink)
Franko914
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The radiator measures 34” in width. Each fan is 17” and bit in width. In order for the two fans to fit, they have to be trimmed a bit and I chose to do this where they will be attached. Pic #6 shows the fans where they will be cut and trimmed at alternating sections (I first used the metal cutting disc but resorted to a hacksaw for cleaner cuts).

An “X” indicates a waste section to be cut/discarded. The corresponding section on the other fan will be retained. An unmarked section will be retained. Its corresponding section on the other fan will be indicated with an “X” and cut/discarded. This trimming will be just enough for the assembly to fit snugly in between the radiator side tanks (well, okay, I cheated at 3:00 a.m. and used a blow torch on one corner to soften the material enough…).
Attached Images
File Type: jpg 06_CoolingFans-CentersToCut.jpg (65.4 KB, 506 views)
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Mad Franko
98 4WD Tahoe 6.5TD 215k Z-71 LT; Remote Mount Dual Reusable SS Oil Filter; Racor 10micron Fuel Filter; K&N Air Filter w/10' Oiled Cotton Gauze Prefilter; SS Diesel Supply FSD w/Cooler; Spare FSD on Same Cooler; HD Hellwig Sway Bars Front/Rear; OPS Bypassed for Lift Pump; 230 Amp Iraggi Alternator; RunCool Dual SS Hood Louvres; 285x75x16 Chapparal A/P; Mechanical Turbo Boost Gage; IP replaced at 100k and 200k miles; Shrouded Dual Electric Cooling Fans @6,000+CFM total; Rear-Facing 12 Gauge Remington 870 for TailGaters.

Soon: "F" Uppper/Lower Intakes; Vacuum+Pyrometer/EGT+Differential Oil Pressure+Differential Fuel Pressure Gages; Extended Glow Controller; High Idle Switch; MAP Boost Fooler; Two-Stage Water Mist Injection; Hitch Mount Fold Down Spare Tire Carrier; Electric Fans for Hood Louvers.

Enforce the First Gun Law: The Second Amendment
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Old 04-08-2008, 12:32 AM   #4 (permalink)
TurboTahoe
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Wow Franko, that looks serious. How are you going to control the fans turning on and off?

Rob
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1995 2-door 1/2 ton Tahoe 6.5 TD. Red/Silver Two-Tone with Grey Leather. Positraction Rear End, 3.73, 4L80-E, 4WD, HyperTech chip, Flowmaster crossover and downpipe, modified intake plenum, '97 air cleaner assembly with factory filter, 3" lift, Model 280 flex-a-lite electric fans (which solved cooling problems caused by body lift), Centerline wheels, PowerSlot brake rotors, 175K miles. Hellwig front and rear swaybars. Rancho adjustable shocks on all 4 corners, Heath Remote mount FSD. 0-60 in 9.5 seconds.

1999 3/4 Ton Suburban 6.5 TD SLT Kid Hauler. 124K miles. Black with Tan leather. Hellwig sway bars front and rear. Flowmaster downpipe. Remote FSD under-the-bumper with Kennedy 72" harness and SSDiesel FSD Cooler. PowerSlot brake rotors. THIS RIG IS FOR SALE HERE: https://www.dieselplace.com/forum/45-...condition.html
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Old 04-08-2008, 12:32 AM   #5 (permalink)
Franko914
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Pics #7 and #8 show the dual fan assembly. I used aluminum rivets mostly. A piece of 1/8” by 3/4" flat aluminum bar cut to 20” in length was placed on one side of the cut/aligned center section of the assembly and riveted in place to reinforce the attachment of the fan shrouds. The bar was a tad longer than necessary but it is easily trimmed with an abrasive disk on the grinder. Steel 90 degree brackets were riveted to the top and bottom of the flat bar.

A 1/8” by 3/4" aluminum angle was riveted to the top of the fan shrouds and to the steel brackets. A 1/8” by 1” steel angle iron was riveted to the bottom of the fan shrouds and bolted to the steel brackets (nuts + locknuts + thread locker). This steel angle iron will be inserted into the gap between the bottom of the radiator and the radiator support lip.
Attached Images
File Type: jpg 07_DualCoolingFans-Front.jpg (69.0 KB, 663 views)
File Type: jpg 08_DualCoolingFans-Rear.jpg (74.6 KB, 345 views)
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Mad Franko
98 4WD Tahoe 6.5TD 215k Z-71 LT; Remote Mount Dual Reusable SS Oil Filter; Racor 10micron Fuel Filter; K&N Air Filter w/10' Oiled Cotton Gauze Prefilter; SS Diesel Supply FSD w/Cooler; Spare FSD on Same Cooler; HD Hellwig Sway Bars Front/Rear; OPS Bypassed for Lift Pump; 230 Amp Iraggi Alternator; RunCool Dual SS Hood Louvres; 285x75x16 Chapparal A/P; Mechanical Turbo Boost Gage; IP replaced at 100k and 200k miles; Shrouded Dual Electric Cooling Fans @6,000+CFM total; Rear-Facing 12 Gauge Remington 870 for TailGaters.

Soon: "F" Uppper/Lower Intakes; Vacuum+Pyrometer/EGT+Differential Oil Pressure+Differential Fuel Pressure Gages; Extended Glow Controller; High Idle Switch; MAP Boost Fooler; Two-Stage Water Mist Injection; Hitch Mount Fold Down Spare Tire Carrier; Electric Fans for Hood Louvers.

Enforce the First Gun Law: The Second Amendment
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Old 04-08-2008, 12:36 AM   #6 (permalink)
Franko914
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Pics #9, #10 and #11 show the assembly installed behind the radiator. Compare to #1 and #2 above. The weight of the assembly is less than thaf of the stock fan/clutch assembly, AND BOTH ARE OFF THE ENGINE! I designed the fan assembly retaining brackets to hold the fans down against the radiator support and forward against the radiator.
Attached Images
File Type: jpg 09_DualCoolingFans.jpg (51.2 KB, 719 views)
File Type: jpg 10_DualCoolingFans.jpg (58.3 KB, 789 views)
File Type: jpg 11_DualCoolingFans.jpg (51.1 KB, 728 views)
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Mad Franko
98 4WD Tahoe 6.5TD 215k Z-71 LT; Remote Mount Dual Reusable SS Oil Filter; Racor 10micron Fuel Filter; K&N Air Filter w/10' Oiled Cotton Gauze Prefilter; SS Diesel Supply FSD w/Cooler; Spare FSD on Same Cooler; HD Hellwig Sway Bars Front/Rear; OPS Bypassed for Lift Pump; 230 Amp Iraggi Alternator; RunCool Dual SS Hood Louvres; 285x75x16 Chapparal A/P; Mechanical Turbo Boost Gage; IP replaced at 100k and 200k miles; Shrouded Dual Electric Cooling Fans @6,000+CFM total; Rear-Facing 12 Gauge Remington 870 for TailGaters.

Soon: "F" Uppper/Lower Intakes; Vacuum+Pyrometer/EGT+Differential Oil Pressure+Differential Fuel Pressure Gages; Extended Glow Controller; High Idle Switch; MAP Boost Fooler; Two-Stage Water Mist Injection; Hitch Mount Fold Down Spare Tire Carrier; Electric Fans for Hood Louvers.

Enforce the First Gun Law: The Second Amendment
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Old 04-08-2008, 12:39 AM   #7 (permalink)
Franko914
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Pics #12 and #13 show some details of the adjustable retaining brackets fabricated out of leftover electrical U-channel and heavy steel 90 degree angle brackets cut to a very short “L” shape. I cut a piece of the angle bracket to secure the U-channel using existing anchor points. I tapped one of the holes in the angle bracket to use as a ground for the fans. Note the clear PVC tube to the right with a bit of silicone – this leads to the temperature probe that was inserted into the fins through the front of the radiator.
Attached Images
File Type: jpg 12_RetainingBracket.jpg (63.9 KB, 683 views)
File Type: jpg 13_RetainingBracket.jpg (54.1 KB, 351 views)
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Mad Franko
98 4WD Tahoe 6.5TD 215k Z-71 LT; Remote Mount Dual Reusable SS Oil Filter; Racor 10micron Fuel Filter; K&N Air Filter w/10' Oiled Cotton Gauze Prefilter; SS Diesel Supply FSD w/Cooler; Spare FSD on Same Cooler; HD Hellwig Sway Bars Front/Rear; OPS Bypassed for Lift Pump; 230 Amp Iraggi Alternator; RunCool Dual SS Hood Louvres; 285x75x16 Chapparal A/P; Mechanical Turbo Boost Gage; IP replaced at 100k and 200k miles; Shrouded Dual Electric Cooling Fans @6,000+CFM total; Rear-Facing 12 Gauge Remington 870 for TailGaters.

Soon: "F" Uppper/Lower Intakes; Vacuum+Pyrometer/EGT+Differential Oil Pressure+Differential Fuel Pressure Gages; Extended Glow Controller; High Idle Switch; MAP Boost Fooler; Two-Stage Water Mist Injection; Hitch Mount Fold Down Spare Tire Carrier; Electric Fans for Hood Louvers.

Enforce the First Gun Law: The Second Amendment
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Old 04-08-2008, 12:42 AM   #8 (permalink)
Franko914
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Pics #14 and #15 show the adjustable thermostat controller anchored to the firewall (I got carried away, okay?). I had initially intended to place it inside an enclosure but decided not to. I placed a spring under the knob before pushing the knob onto the controller to help keep it from turning easily. I inserted the temperature probe and capillary tube through clear PVC tubing for protection. I sealed the tube openings with clear silicone. The probe extended completely through the other opening to be inserted through the radiator fins. The manual switch is located in-cabin.
Attached Images
File Type: jpg 14_TemperatureController.jpg (51.1 KB, 710 views)
File Type: jpg 15_TemperatureController.jpg (67.0 KB, 398 views)
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Mad Franko
98 4WD Tahoe 6.5TD 215k Z-71 LT; Remote Mount Dual Reusable SS Oil Filter; Racor 10micron Fuel Filter; K&N Air Filter w/10' Oiled Cotton Gauze Prefilter; SS Diesel Supply FSD w/Cooler; Spare FSD on Same Cooler; HD Hellwig Sway Bars Front/Rear; OPS Bypassed for Lift Pump; 230 Amp Iraggi Alternator; RunCool Dual SS Hood Louvres; 285x75x16 Chapparal A/P; Mechanical Turbo Boost Gage; IP replaced at 100k and 200k miles; Shrouded Dual Electric Cooling Fans @6,000+CFM total; Rear-Facing 12 Gauge Remington 870 for TailGaters.

Soon: "F" Uppper/Lower Intakes; Vacuum+Pyrometer/EGT+Differential Oil Pressure+Differential Fuel Pressure Gages; Extended Glow Controller; High Idle Switch; MAP Boost Fooler; Two-Stage Water Mist Injection; Hitch Mount Fold Down Spare Tire Carrier; Electric Fans for Hood Louvers.

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Old 04-08-2008, 12:45 AM   #9 (permalink)
Franko914
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Pic #16 shows the fuse/relay bank installed on top of the driver side negative battery post. The two (2) left fuse holders have green 30 amp AGC fuses (fog lights and LP). The right (2) fuse holders had green 30 amp AGC fuses, one for each fan, but they kept blowing each time the fans were started by the in-cabin manual switch. To get through the day, I added a second fuse holder with a 30amp fuse in parallel to each fan fuse. Even with two (2) x 30 amp fuses for each fan, one fuse blew in 1 of 5 manual fan starts.

I picked up the green 30 amp AGC blade circuit breakers from AutoZone, which solved the start-up current load fuse-blowing issue. Note: Do Not grasp the circuit breakers to remove them from the fuse holders – use a knife or other thin object to pry them loose… the metal covers of the circuit breakers come off quite easily (ask me how I know). Hence, the black nylon ties…
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File Type: jpg 16_RelaysFuses.jpg (58.1 KB, 464 views)
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Mad Franko
98 4WD Tahoe 6.5TD 215k Z-71 LT; Remote Mount Dual Reusable SS Oil Filter; Racor 10micron Fuel Filter; K&N Air Filter w/10' Oiled Cotton Gauze Prefilter; SS Diesel Supply FSD w/Cooler; Spare FSD on Same Cooler; HD Hellwig Sway Bars Front/Rear; OPS Bypassed for Lift Pump; 230 Amp Iraggi Alternator; RunCool Dual SS Hood Louvres; 285x75x16 Chapparal A/P; Mechanical Turbo Boost Gage; IP replaced at 100k and 200k miles; Shrouded Dual Electric Cooling Fans @6,000+CFM total; Rear-Facing 12 Gauge Remington 870 for TailGaters.

Soon: "F" Uppper/Lower Intakes; Vacuum+Pyrometer/EGT+Differential Oil Pressure+Differential Fuel Pressure Gages; Extended Glow Controller; High Idle Switch; MAP Boost Fooler; Two-Stage Water Mist Injection; Hitch Mount Fold Down Spare Tire Carrier; Electric Fans for Hood Louvers.

Enforce the First Gun Law: The Second Amendment
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Old 04-08-2008, 12:48 AM   #10 (permalink)
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Quote:
Originally Posted by Franko914 View Post
Each fan has an all-enclosed plastic shroud (see note later on this important feature), silent S-blades, a powerful motor that draws 18 amps and a 3,000+ CFM rating.
36 amps?

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