New Aluminum Radiator & Electric Fan don't fit!

[cgbexec]

I was working on my project Bronco this weekend and I was so frustrated I wanted to cry.

I broke open the new Howe Aluminum Radiator. Man that radiator looks sweet. I bolt in my new lower stainless steet radiator mounts. I drop the radiator in and it doesn't quite fit into the new stainless mounts.:-[ No problem, I unbolt them and break out my dremel with a cut-off wheel attached. I make short work of the mounts. I bolt them back in and drop the radiator in and it fits. Now I mount the top mounts and tighten everything up. I grab my brand new Black Magic S-Blade 16" Electric Puller Fan nd it doesn't fit between the radiator and the water pump. Not even close. The radiator is a 2 core aluminum, but it is as thick as a 4 core copper.

What would you guys do?

Ditch the radiator.

Ditch the fan for a thinner one? %)

 

[Crewwzin]

I was working on my project Bronco this weekend and I was so frustrated. I broke open the new Howe Aluminum Radiator. Man that radiator looks sweet. I bolt in my new lower stainless steet radiator mounts. I drop the radiator in and it doesn't quite fit into the new stainless mounts.:-[ No problem, I unbolt them and break out my dremel with a cut-off wheel attached. I make short work of the mounts. I bolt them back in and drop the radiator in and it fits. Now I mount the top mounts and tighten everything up. I grab my brand new Black Magic S-Blade 16" Electric Puller Fan doesn't fit between the radiator and the water pump. Not even close. The radiator is a 2 core aluminum, but it is think like a 4 core copper.

What would you guys do?

Ditch the radiator.

Ditch the fan for a thinner one? %)

What kinda water pump are you using? Some of the pumps for a 302 are just downright huge and wont allow for a radiator to fit.

You could also modify your core support to move the radiator closer to the grille.

 

[Madgyver]

Move the radiator core support forward... but that's me....

I had the same problem... The electric fan is still in the box... and I've already gone through a couple of rads..

 

[greasypigeon]

Can the fan be made into a pusher. Thats what I had to do.

 

[cgbexec]

The water pump is correct because all of the pulleys line up without any problems. If I had a shorter pump, then the powersteering and the alternator would not line up.

I could modify the core support, but I was trying to avoid cutting the truck up and welding things now that everthing is painted. I am leaning towards a thinner twin fan set up, but I wanted to hear everyone's opinions. I will post a picture tonight of the distance between the radiator and the nose of the waterpump pulley.

 

[cgbexec]

Can the fan be made into a pusher. Thats what I had to do.

The fan can push, but there is not enough room in front of the radiator either unless I remove the stock hood latch and pin the hood.

 

[bmc69]

I have that exact electric fan sitting in a box on the shelf..slightly used. OF all the various combinations of fans and thingsI tried to get my 408 cooled, that fan was the worst of the lot.

I'm hoping it is enough fan to keep the 4.0L V-8 cool in another EB project..cuz it sure was wimpy for my 408.

I guess the moral of my post is: Don't shed too many tears if ya have to toss that Flex-a-lite option for a mechanical fan.

 

[Crewwzin]

The water pump is correct because all of the pulleys line up without any problems. If I had a shorter pump, then the powersteering and the alternator would not line up.

I believe that if you get all the accessories off the front of an Explorer motor you wont have this problem. IIRC, it has a very short water pump and all the other stuff is designed around it.

 

[surfer-b]

I had the same problem only I am using a WH 4 core (super cooler I believe) and a derale 16" puller. I didn't want to mount it in front because of the stock latch system as you stated and also because of the AC condensor. Luckly I checked before I had it painted. I cut the stock Rad mounting brackets off and moved the RAD all the way aginst the core support and fabed new brackets. Even then I had to offset the fan just a small amount to clear the WP pully.

 

[cgbexec]

I had the same problem only I am using a WH 4 core (super cooler I believe) and a derale 16" puller. I didn't want to mount it in front because of the stock latch system as you stated and also because of the AC condensor. Luckly I checked before I had it painted. I cut the stock Rad mounting brackets off and moved the RAD all the way aginst the core support and fabed new brackets. Even then I had to offset the fan just a small amount to clear the WP pully.

I will take another look when I get home. I didn't want to cut anything, but the more I think about it, the more I am not going to have a choice. The Black Magic Fan is only 4.5" thick and it is not even close to fitting. My guess is even if it was 3" thick, it would just barely fit and there are not any fans that thin that can do the primary cooling on a 350 H.P. engine and still fit this narrow radiator.

 

[oleguy74]

becool.com/#products.this web site.they make fans and rads just for eb's.part#75014 16 x 16 x2 1/2" 1610 cfm.#75058-16 x 16 2 1/2" 1300cfm, 75083 14 x 14 x 2 1/2 " 960 cfm. #75021 relay 195 deg-on 175 deg off..#75032 185 on-165 off. (800)515-6075. ask for kirk.

 

[TN1776]

The Black Magic Fan is only 4.5" thick and it is not even close to fitting.

There's your problem! Without pushing the core support forward, I doubt even with Explorer front dress you'd be able to mount a 4.5" thick fan.

I bought a 16" Derale fan, rated at 2100 or so CFM and its about 2.6" thick. Clearance is tight but a Derale rep said he is comfortable in recommending as little as 1/2"-3/4" between the fan and H2O pump. I have something like 5/8" clearance, and that was with fabbing my own mounts that pulled the radiator closer to the core support. If its not enough I'm not opposed to cutting my core support and pushing it out towards the grill a others have done. I also offset the fan for a little more clearance.

 

[cgbexec]

There's your problem! Without pushing the core support forward, I doubt even with Explorer front dress you'd be able to mount a 4.5" thick fan.

I bought a 16" Derale fan, rated at 2100 or so CFM and its about 2.6" thick. Clearance is tight but a Derale rep said he is comfortable in recommending as little as 1/2"-3/4" between the fan and H2O pump. I have something like 5/8" clearance, and that was with fabbing my own mounts that pulled the radiator closer to the core support. If its not enough I'm not opposed to cutting my core support and pushing it out towards the grill a others have done. I also offset the fan for a little more clearance.

Will 2100 CFM cool a 302 bored .030 over putting out 328 H.P. and 350 ft. lbs. of torque? The Black Magic fan is rated at 3000 CFM, but since it doesn't fit it does not matter what it output is. I was trying to go fully electric fan, but I suppose I could put a shroud on it and run a mechanical fan.

 

[sstlaure]

I went tubular core support on my truck and ended up with 5" between the water pump and the radiator (With the Howe Alum installed.)

 

[76 bronco J]

There's your problem! Without pushing the core support forward, I doubt even with Explorer front dress you'd be able to mount a 4.5" thick fan.


sure it will even with a thicker than stock radiator, although I did grind down the explorers threaded water pump snout that is used with the stock clutch fan setup for slightly more clearance insurance>>>>> I've had excellent results using the older regular black magic fan with the straight blades & 14 amp draw rating versus the newer S bladed 18 amp version talked about in this thread. I also realize the much higher amp drawing taurus/sable/continental/t-bird fans are the prefered choice for electric fan usage . The cowl induction hood regardless of it's intented usage or peoples beliefs plays a big part in making any cooling system/engine combo work easier at idle or putting along by releasing the naturally rising(science 101) trapped heat . The cowl hood also keeps the engine compartment the most dry & clean on the early bronco compared to other methods of venting by utilzing the early broncos upper firewall as a gutter system. I had issues with the stock motor/radiator/fan/hood combo creeping while sitting or putting along in super hot weather & yes everything was plenty up to par cleanliness & maintenance wise. The current setup is a aluminum headed 302 crate motor rated at 315hp(Y303 heads,E303 cam) into duff's aluminum radiator along with the C4 trans plumbed only to the radiator with no external cooler(afco brand, they may have a different supplier now). The motor tops out at 190 degrees max in full blown houston dead stop traffic at any temperature & the trans will creep to 200 measured at the pan. I didn't reinstall AC yet so things may change for sure with that in the mix,but I had problems stock even with it off .

 

[76 bronco J]

>>>>>>>> here's a better pic showing the clearance with the fan. The pic shows how the overall fan depth is more at the center of the fan motor compared to the blades ....remember, This is also with the 2 core 1 inch tube radiator so clearance would be considerably better with a stock width type radiator.............

 

[cgbexec]

I looked at it last night briefly and I could gain about 3/4 of an inch by cutting off the factory radiator brackets and moveing the radiator forward up against the core support. That however would not gain me enough space to use the Black Magic S fan. Most of the twin fans won't fit on the radiator core. I need a single thin fan that can pull enough air to cool a 328 H.P. 302.

So what do you guys suggest?

I hate the fact that every little project that I think should take a couple of hours turns into a major project requiring new parts and complete re-engineering of the EB.

I need to have a Bronco completion party, but too bad that most of you guys live way to far from me. :-[

 

[76 bronco J]

I hate the fact that every little project that I think should take a couple of hours turns into a major project requiring new parts and complete re-engineering of the EB.

:-[

,,,,,,,,,that's so so true & a bit discouraging to say the least, but a fact you must accept when you modify.....I'd seriously consider going the explorer serpentine route before any other option. The fact that the 96-01 explorer even came the old 5.0 pushrod motor was amazing enough & the fact that the super compact serpentine belt systems fit our early broncos so perfect is truly a gift we early bronco owners should not pass on..........