After my ebay special thermofan failed, i decided to fit a decent fan into zook from an AU Falcon, thought I might take images as i go.
These are the fans in their original configuration. You only need one of them, i just happened to use the left one in this picture. Thanks to B4T from this forum for givin it to me.
Chopped in half and looking rather used. After test fitting the fan, it looks like it would hit the water pump, so it needs some trimming so the fan will sit closer to the radiator.
You can see there is a step from the face of the radiator fins to the mounting surface of the thermofan. This means you can trim more from around the thermofan to get it even closer to the radiator for maximum external clearance around the waterpump.
After measuring and trimming 12mm from right around the edges, this is what you should see. The nosecone of the fan will stick out a tiny bit, this is what sticks down past the mouting surface but still does not contact the radiator thanks to the step.
Three out of the four edges are square and straight. The edge that is not straight is the one thats cut when separating the two fans.
Line the longest straight edge up with the top of the radiator and plan how you are going to do the mounts.
The thermofan will be too wide for the suzuki radiator, so you need to chop it down so you can easily bolt it up to the radiator. I had to remove 30mm from the edge.
After chopping the 30mm off, it is now behind the mounting boltholes on the radiator.
Now start measuring and making youre mounts. I used some sheetmetal i found lying around. It was an old Volvo sign. I used sheetmetal as its easy to mould to the rounded contours of the fan shroud, and its easy to bend.
I made the mounts on the underside of the thermo shroud as it looks neater, plus it was easier moulding the sheetmetal to the inside edges n curves than the outside.
All mounts made and bolted up. Riveting would have been just as easy, but rivets and plastic tend to come loose and fret themselves free.
None of the 6x15mm bolts stick out enough to touch the radiator when mounted up.
At least three bolts per mount made them pretty stiff.
All bolted up to radiator. I will fab up some small shrouds so 100% of air is drawn through radiator.
Another gap that needs shrouding. This is the edge I cut 30mm off.
After fitting the radiator and thermo back into zook, i noticed that the crank pulley hit the thermo. I tried to shave some plastic off the thermo as you can see in the pic, it just cleared, but i ended up spacing the bottom two mounts between the radiator and the chassis out about 5mm so the pulley had plenty of room for any movement.
