Digging this up for update.
I'm bolting my radiator in, and fan and clutch and shroud and low and behold: I've done such a good job keeping the front serp tight, only about 1/4 of the fan is in the shroud.
I have a 5.0/ Explorer serp and steel 9 blade fan. Using the stock clutch I have roughly 3 inches of space between the front of the top of the fan and back of my stock copper radiator. The bottom of the fan is about 2.5 inches from the rad due to engine tilt using extreme motor mounts.
Wow.
I have looked at four clutches today and none have the steel fan bolt pattern. The best "longer" clutch was off a 2001 f150 7.1 diesel, but again smaller plastic fan bolt pattern. The previously mentioned non electric Envoys are the smaller bolt pattern as well. I think this may be why this never gets done, I drive around PHX 3 hours a week looking for the wrong part
I've looked through all of 4 Seasons webpage and can only find a previously mentioned clutch number 46049, but that only adds about 3/4 to maybe an inch of longer snout, I'd sure like the 1.5 increase the f150 diesel motor clutch would give. This would prevent the need for a shroud mod.
Two things, I'm calling 4 Seasons Monday to see if they can make or have the longer snout clutch in the right bolt pattern. Barring that, has anyone used the plastic fan which bolts right up? Point to ponder, every fan I find has a warning not to use offroad, in extreme conditions, blah blah. I think its cause they will come apart if you suck in water.
Three options then, hope they make the longer snout clutch, or use a plastic fan knowing it's a risk, or mod the very nice aluminum shroud which will always look odd I think, Anyone add on to shroud? Pics?. Method of attachment, weld, glue, rivit, bolt?
BTW, stock steel explorer fan bolt circle 3.8 inches, fan mount circle is about 3.2 inches. The plastic fan is right at 3 and 2.5 respectively.