Trystan Casey
There are several methods for mounting electric fans to a radiator, with some variations depending on the type of fan and radiator. One common method is to use mounting brackets that attach to the radiator support brackets or framework and then to the fan mounting tabs. These brackets can be purchased or fabricated from angled aluminium, sheet metal, or standard hardware-store angle iron. Another method is to secure the fan directly to the radiator using zip ties or plastic threaded ties, although this is not recommended by some as it can damage the radiator fins and core, leading to leaks. It is important to ensure that the fan does not obstruct the airflow through the radiator and that it is securely in place to avoid damage.
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What You'll Learn
Using mounting brackets
Mounting electric fans to a radiator using brackets is a straightforward process, but it requires careful attention to ensure an effective and secure installation. Here is a detailed guide on how to use mounting brackets for this purpose:
Preparing the Brackets:
You can choose to use prefabricated mounting brackets designed for universal electric fans, or you can fabricate custom brackets to fit your specific application. If you opt for custom brackets, you will need some basic metalworking skills. Cut a length of angled aluminum or sheet metal to size, ensuring it is thick enough to securely hold the fan and withstand vibrations.
Attaching Brackets to the Fan:
Whether you use prefabricated or custom brackets, the process for attaching them to the fan is similar. Align the brackets with the fan housing and drill holes along the sides. Use bolts with nylocks or rivets to securely attach each bracket to the fan shroud. Make sure the bolts or rivets are tight to prevent any unwanted movement or vibrations.
Mounting the Fan to the Radiator:
Once the brackets are securely attached to the fan, it's time to mount the assembly to the radiator. Align the brackets with the radiator frame or core support, ensuring that the fan is positioned correctly relative to the radiator core. Mark the drill holes, and then drill through the marked spots. Finally, secure the brackets to the radiator using bolts or rivets, checking that the fan doesn't obstruct any hoses and that it spins freely by hand.
Additional Considerations:
It is important to ensure that the fan doesn't interfere with the radiator's function. Avoid mounting the fan directly onto the radiator core, as this can reduce the effective cooling area and lead to inefficiencies. Instead, consider using a fan shroud, which allows the entire surface of the radiator to function optimally while still providing a secure mounting point for the fan. Additionally, some fan shrouds have a rubber bulb around the perimeter that seals and cushions the radiator and the fan, further enhancing the setup.
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Drilling holes for bolts
First, it's essential to determine the appropriate location for the electric fan on the radiator. This involves considering factors such as the size of the fan, the available space, and the alignment of the radiator and AC condenser channels. Mark the desired position of the fan on the radiator frame or core support. It is important to note that the fan should not be mounted directly on the radiator core, as it may damage the radiator and affect the efficiency of the cooling system.
Next, select or fabricate the mounting brackets that will secure the electric fan to the radiator. Some electric fans come with mounting brackets that can be attached to the fan using screws. Alternatively, you can choose to make your own brackets for a custom appearance. This requires basic metalworking skills and the use of materials like angled aluminum or sheet metal. Ensure that the brackets are sturdy enough to support the weight of the fan and withstand vibrations.
Now, it's time to drill the holes for the bolts. Align the custom brackets to the fan housing and mark the drill points. Use a drill bit that corresponds to the size of the bolts you will be using. Carefully drill three to four holes along the sides of the brackets. It is crucial to avoid drilling into the water tank or the radiator core, as this can cause leaks and damage to the radiator. Take your time and work with precision to ensure that the holes are drilled accurately and do not compromise the integrity of the radiator.
After drilling the holes, you can attach the brackets to the fan shroud using bolts with nylocks or rivets. Ensure that the bolts are securely fastened but avoid overtightening, as this can damage the threads or create unnecessary stress on the radiator and fan assembly. Once the brackets are in place, you can proceed to mount the electric fan to the radiator by aligning the brackets with the pre-drilled holes on the radiator frame or core support.
Finally, double-check that the fans spin freely by hand and that there are no obstructions, such as hoses or wires, that could come into contact with the blades. This step ensures that the electric fan operates safely and effectively once it is installed and connected.
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Attaching with zip ties
Zip ties can be used to attach electric fans to radiators, although this method is not recommended by radiator manufacturers. This is because the zip ties have to be pushed through the radiator fins, which can cause damage and leaks.
Some people have reported using zip ties to attach electric fans to radiators for many years without any issues. However, others have experienced leaks and damage to their radiators due to the zip ties wearing through the core or radiator channels.
If you choose to use zip ties to attach your electric fan to your radiator, it is important to ensure that the weight of the fan is not supported solely by the radiator. The lower legs of the fan should rest against the bottom lip of the radiator so that the zip ties are only holding it tight, rather than bearing the weight.
It is also recommended to use a structural mount for the fan, attaching it to the frame of the radiator rather than running the zip ties through the fins. This will help to prevent damage to the radiator and ensure the fan is securely attached.
Another option is to use brackets to attach the fan to the radiator, either purchased separately or fabricated from angled aluminium or sheet metal. These brackets should be thick enough to hold the fan securely and withstand vibrations. Align the brackets to the fan housing and drill holes to attach them with bolts or rivets. Then, align the brackets with the radiator frame and drill corresponding holes to secure the fan in place.
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Using a structural mount
To use a structural mount, first identify a suitable location on the radiator frame or core support for the brackets to attach. Most radiators have a frame or mounting flange that is suitable for fan mounting. Avoid using the header plate for mounting, as this can cause damage to the car. Mark the holes where the brackets will mount, then remove the fan and drill the holes. Use the supplied hardware to mount the fan. Check that the fans spin freely by hand and that there are no hoses that can come into contact with the blades before making the electrical connection.
The brackets used in a structural mount should be made from material thick enough to hold the fan and withstand the vibrations found in an automotive application. Typically, a length of angled aluminium or sheet metal is cut to length along either the top and bottom or the sides of the fan. Align the custom brackets to the fan housing and drill three to four holes along the sides. Use bolts with nylocks or rivets to attach each bracket to the fan shroud.
Some electric fans come with mounting brackets that can be attached to the fan using the supplied screws. The fan shroud has a rubber bulb around the perimeter that seals it against the radiator core and cushions both the radiator and the fan. However, custom brackets can also be fabricated if desired, which requires some basic metalworking skills.
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Ensuring adequate airflow
When installing an electric fan, it is important to consider the conflicting requirements of low-speed fan operation and high-speed unassisted airflow. One way to mitigate this is to fit fans of the maximum size. Fans with efficiently shaped blades and less total blade area will present less of a flow restriction when not running. However, as you reduce blade area, you need a better blade shape and higher fan RPM when running to move enough air.
To ensure adequate airflow, it is recommended to use a \"pull\" fan mounted on the engine side of the radiator, as it does not interfere with airflow at highway speeds. The fan should not be mounted directly on the radiator, as it will only draw air through the area in front of the fan and not utilise the entire area of the radiator, reducing the efficiency of the cooling system. Instead, the fan should be mounted on a shroud, which allows the whole surface of the radiator to function correctly. The shroud design is crucial, as it ensures that the fan pulls air through the entire core of the radiator, maximising its cooling effect.
When installing the fan, it is important to ensure that it spins freely and does not interfere with any hoses or other components. Additionally, the radiator design should allow for effective airflow, with wider and taller radiators generally providing better airflow than thicker ones.
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Frequently asked questions
The best way to mount an electric fan is to use metal brackets that attach to the radiator support brackets and then to the fan mounting tabs. This can be done using standard hardware-store angle iron.
It is not recommended to use zip ties to mount an electric fan to a radiator as this can cause damage to the radiator fins and put tension on the core. However, some people have used zip ties without any issues and some fans come with plastic ties for this purpose.
Application-specific electric fans are designed to fit specific vehicles and are usually easy to install. Universal fit fans may require some customisation but are still usually easier to install than you might think.
