Electric Fans - Flex-a-Lite kit doesnt cut it. Need ideas - Dodge Cummins Diesel Forum
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post #1 of 188 (permalink) Old 12-01-2015, 10:12 PM Thread Starter
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Electric Fans - Dual Volvo fan built to beat Flex a Lite

Here is my final update:

I gave up on my volvo fans. I am towing too heavy now moving across the country and back in the next few years and need the CFM of a mechanical fan. They worked great in a light duty towing, and daily driver on road setup, but not when you're pushing the truck too hard in the dirt under the desert sun, or hauling equipment to a ranch on winding backroads up and down big grades.

I also gave up on the stock 3rd gen electro-hydraulic fan clutch after cutting another set of wires with the OEM unit I installed to get across the country on my first outing into the woods of the northeast.

Instead I have installed the following parts, ordered from RockAuto:
1999 DODGE RAM 2500 PICKUP 8.0L V10
HAYDEN 2791 Radiator Fan Clutch $ 38.79 $ 0.00
2001 FORD F-250 SUPER DUTY 7.3L V8 DIESEL Turbocharged
MOTORCRAFT YA225 Radiator Fan Blade $ 71.79

Total delivered to my door was $115.

1999 V10 severe duty fan clutch had the correct thread pitch, the 7.3 fan bolted right up with some metric hardware, and the fan leaves a ~1" gap to the shroud.
Haven't had any issues at all, but its not summer at 24000lbs gross yet.


If anybody is interested in my fan setup, it worked when pulled, wiring is complete, and it comes with an extra fan/motor. $180 plus the ride.



ORIGINAL POST
_____________________________

OK. Here are the details of my fans/shroud setup.

16 gauge galvanized sheet, 1 inch shroud depth. 26.25"x 29.5" inside dimensions. I used a sheet metal brake to bend the edges, and a plasma cutter to cut out the circles. (<$70 material cost)

Parts:
*Volvo 2 speed fans and controllers, I took mine from a 97 S70 and a 98 V70XC. Any late 90s era volvo should work, but i took mine from turbo cars. ($20-50/each)
*Hollister Road 1.75" 304 stainless pipe with M14x1.5 bung and a 1/2 NPT bung for a coolant bypass dump. You could do 2" as well, must ask for custom 2 unit ($55)
*Trunk lid weatherstripping from junk yard
*BMW 91/99C low/high thermister BMW# 61311378073
*BMW wiring harness parts for thermister:
-1x 90 degree connector BMW# 61131378412
-2x high/low trigger wires BMW# 61130007445
-1x ground wire BMW# 61130007446
*Volvo Relay PN# 1398845 (just take these with the fans at the JY, plus all the wire you can get your hands on)
*2x Standard 5 pin relays
*1x



*Good quality heat shrink electrical connectors (


)

Sketch


Wiring Diagram. I added another relay wired the same as the IGN switched relay to use a hot A/C control wire tap to trigger a ground which I tapped into the High speed control circuit


Cut to size, 1" edges bent, 15 7/8" diameter holes cut


Divider welded in and trunk lid weather stripping mocked up


mounting tabs welded. If I did it again I would weld them flush with the shroud height, butt welded to the edge to make installation easier. used the factory fan shroud for dimensional reference


Fans riveted on, relays and controllers also, plus a coat of paint.


More info is found scattered through this thread, but this has been the bulk.
Good luck, and may cool temperatures be with you.






Begin Original Post:
I installed the Flex-a-lite fans after my stock clutch wires decided to get in the way of the fan - ruining the radiator, fan, and clutch.

Not happy. The flex fans work fine on the highway, but at low speeds chugging up long winding back road hills they dont cut it, not to mention raging in the dirt... I kept pushing it one time to see if the temps would stabilize, but quit when I hit 245

I Need ideas. I was in a pinch and needed to get the truck back on the road, but now have time to around and figure out a real solution.

I've installed a set of Ford Windstar fans on a project before, and have heard about the legendary Taurus fans. I am contemplating trying to offload these things and getting a pair of Taurus fans....

Need MOAR CFM!


06 silver QCSB. Carli 3" dominator w/LT bags, diff cover, BJs, truss, hydro assist. Yukon locking hubs, LS rear, ELocker front. Edge w attitude. Bumper, flatbed, winch, sliders, tools, rack, OBA, CVT RTT http://blog.carlisuspension.com/2014...ong-drive.html
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post #2 of 188 (permalink) Old 12-01-2015, 11:57 PM
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Quote:
Originally Posted by rwright07 View Post
I installed the Flex-a-lite fans after my stock clutch wires decided to get in the way of the fan - ruining the radiator, fan, and clutch.

Not happy. The flex fans work fine on the highway, but at low speeds chugging up long winding back road hills they dont cut it, not to mention raging in the dirt... I kept pushing it one time to see if the temps would stabilize, but quit when I hit 245

I Need ideas. I was in a pinch and needed to get the truck back on the road, but now have time to around and figure out a real solution.

I've installed a set of Ford Windstar fans on a project before, and have heard about the legendary Taurus fans. I am contemplating trying to offload these things and getting a pair of Taurus fans....

Need MOAR CFM!
Taurus fans are dual speed... they work good but I don't see them working... if you did get two of them you would have to have a switch for the high and low.. I had one on a 390fe ford but it would over heat in the summer at 5 way lights.

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post #3 of 188 (permalink) Old 12-02-2015, 12:51 AM
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Where are you located? I run no fans unless in competition or beatin on it at ambients of 90*+. Do you have a coolant bypass?

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post #4 of 188 (permalink) Old 12-02-2015, 01:27 AM
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All you need to know..

https://www.cumminsforum.com/forum/ge...t-chamber.html

The post with the good info...

https://www.cumminsforum.com/forum/ge...l#post19521922

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post #5 of 188 (permalink) Old 12-02-2015, 02:11 AM Thread Starter
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Been doing some digging.

What's better than a Ford Taurus fan? A taurus fan from a better application... - Pirate4x4.Com : 4x4 and Off-Road Forum

Looks like the 90s volvos have the same fan motor as the Taurus, but a more easily adaptable housing. They also come with a beefy relay setup.

These folks figured out how to use a BMW dual temp cooling fan switch to trigger the high and low speeds (195/210 L/H)
Budget Dual Fan Controller Setup / Taurus Fan Setup - NastyZ28.com

I think I will build a shroud and put together a better setup than Flex-a-Lite chose to in all their infinite wisdom...
https://www.cumminsforum.com/forum/3r...ml#post4218458

2 fans in a shroud with high/low triggered by a dual temp sender and my A/C with manual off override?

thoughts?

06 silver QCSB. Carli 3" dominator w/LT bags, diff cover, BJs, truss, hydro assist. Yukon locking hubs, LS rear, ELocker front. Edge w attitude. Bumper, flatbed, winch, sliders, tools, rack, OBA, CVT RTT http://blog.carlisuspension.com/2014...ong-drive.html
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post #6 of 188 (permalink) Old 12-02-2015, 02:12 AM Thread Starter
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Thanks steve! looks like there is no need to reinvent the wheel. Lots of work done on the subject already here:
https://www.cumminsforum.com/forum/3r...l#post18938121

06 silver QCSB. Carli 3" dominator w/LT bags, diff cover, BJs, truss, hydro assist. Yukon locking hubs, LS rear, ELocker front. Edge w attitude. Bumper, flatbed, winch, sliders, tools, rack, OBA, CVT RTT http://blog.carlisuspension.com/2014...ong-drive.html
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post #7 of 188 (permalink) Old 12-02-2015, 02:20 AM
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Read this...

https://www.cumminsforum.com/forum/3r...l#post18938121

volvo has a controller, needs the control lines to be pulled low, 140~150 ma current draw...

You want the straight blade fan, draws more CFM than the S blade version and just 90 cfm less than the taurus fan. The preferred volvo fan draws 3600+ cfm on hi on the bench with battery connected to a charger. Installed it would be higher. Spooled05 did 2 taurus fans and had no trouble towing over 20k gvwr. His setup did not have a divided shroud which means it was not running up to its full potential. Divide the shroud and the volvo dual fan setup should be good for at least 7200 cfm with both fans on hi. In reality its more due to the higher battery voltage in the truck. I have no way of measuring that though.

the volvo fans draw just 28~29 amps on high, have their own controller and are dirt cheep. Get the fan from a '97 or newer 850 and you'll have the straight blade fan in hand.

AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 430k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #8 of 188 (permalink) Old 12-02-2015, 02:28 AM
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You will want this...

304 Stainless 2.0" Single 3/8" Bung :: The Hollister Road Co.

if you are planning to use the dual temp sensor...

AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 430k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #9 of 188 (permalink) Old 12-02-2015, 11:50 AM
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Quote:
Originally Posted by Broaner View Post
Do you have a coolant bypass?
If not, getting one will help a lot.

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post #10 of 188 (permalink) Old 12-02-2015, 02:16 PM
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Good point Broaner, my Flex a lites did not previolsly cut in low enough until I installed my twin set up and a coolant bypass. Never really thought about that being why they seem to work better now. Thanks for the input!

05 2500 HPTuner, MPI 62/480, BBi 2, ADII, stroker/stock CP3's, Carrillos,Coated pistons, Girdle, ARP625, Hellman sidedraft, full port, oversize valves, fire rings, Fluidampr, Hamilton188/220, 110's, HD pushrods, BOV, Full Billet Goerend,full Carli, CalTracs, SSBC
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post #11 of 188 (permalink) Old 12-02-2015, 02:33 PM
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Pardon my ignorance. Why go electric?

What are the inadequacies of the stock fan/fan-clutch?

'06 Mega 3500 Laramie 4x4 SRW | efibyryan | Firepunk Comp 1 | CTS2 Gauges| Tater-Built 62/65 HE351| 4" Flo~Pro tbe |30" FTE Resonator| Fass 150 | Bean's sump
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post #12 of 188 (permalink) Old 12-02-2015, 02:44 PM
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Mine holds a much steadier temperature now at a ll times. Lliving in a hot area the one fan on the Flex a Lite is always on when the A/C is running. In prolonged periods of stop in go traffic it really helps keep your A/C running cold vs. the factory set up with the fan always pulling air when you are stopped.

05 2500 HPTuner, MPI 62/480, BBi 2, ADII, stroker/stock CP3's, Carrillos,Coated pistons, Girdle, ARP625, Hellman sidedraft, full port, oversize valves, fire rings, Fluidampr, Hamilton188/220, 110's, HD pushrods, BOV, Full Billet Goerend,full Carli, CalTracs, SSBC
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