hans14914

Well, I think its done. Shroud has been reduced in height slightly. The intake snouts have been redesigned to be more like the S4 to allow use of pre-existing intake solutions (Kuhn and VCB snouts). The flange inside the fan shroud have been extended to match the S4 radiator core exactly, providing the best seal. Upper contour has been remodeled to match the S4 fan shroud.

Like the original iteration, you can see that the shroud easily clears the cooler lines. It is quickly removable by removing the two topside screws, lower mounts are tabs like the S4.

Lets see what the shop says about the revisions.

Thanks
Hans

Rob Edwards

Since no product announcement ever evades additional suggestions from the peanut gallery, how hard would it be to model some sort of plastic lip that would 'top' the top of the radiator, to provide a modicum of heat rejection for the air inlets. A la PorKen's old rubber radiator cover thingee? Or Jim Mayzurk's?

MjRocket

I 2nd that idea, this would be the icing on the cake and I would think easy enough to incorporate.

I had looked into getting one of these in the past, but came up short.

Ducman82

how are the snouts going to be made? printed?

Speedtoys

Yes please!

Ducman82

i did not see this posted, but isn't that spal fan a pusher?

hans14914

Rob - I don't really see a need to fabricate a heat-shield for this application. It seems more logical to use a die-cut piece of insulation in that sheet metal tray, or some peel-and-stick product from a company like DEI maybe:

http://www.designengineering.com/cat...s/reflect-cool

There just isnt a lot of room for an additional piece of material and stand-offs in that location.


Jake - The test parts are currently be printed as we speak. I have a pair of snouts coming out of the wash tank tomorrow afternoon. Production parts will either be urethane cast or composite lay-up... whichever is more cost effective. In regards to the fan, I was being lazy and found a fan with the same shroud on GrabCAD. I didn't want to bother with drawing the actual fan. In the first post, I have model numbers listed for the correct sealed puller fans.

Will get pictures of the new snouts up tomorrow, along with some comparison pictures to the factory S4 fan shroud.

Thanks
Hans

MjRocket

Hans

Checked out that link, that product looks like a Great alternative, I think most everyone could benefit from this even if they dont upgrade to your shroud.

Thx

DZGunner

When do you think this will be finished?

and how well do you think it would compare to this: http://www.928motorsports.com/parts/...diator_fan.php

I need to replace my entire shroud and fan assembly, so i was gonna go ahead and get the 928 Motorsports replacement until i saw this.

69gaugeman

That doesn't exactly fit the rad and looks like it needs some sort of bracketry.

If you are willing to do that, THIS is only 111.00. Cut off the side tabs, a couple of simple brackets and away you go.

Sorry Hans, don't mean to hijack your thread. Yours is a much better fit and uses the stock mounting points, which I am in favour of. But for those who are on a severe budget, this is an alternative.

DZGunner

that doesnt have the air dam at the top though, no fittings for the intake tubes. I'd rather get something thats been fitted and or tested specifically for our cars.

hans14914

On the availability front, It will just depend on what people are willing to pay. If someone had to have this right now, I could send the flat file over to the waterjet shop, have it buzzed out, and then put the bends in myself by hand, or take it to a sheet metal shop I work with. We could finish it with printed snouts. So, I guess the answer is you could have one by Friday if you wanted to pay the one-off penalty. I was planning on getting pricing for a batch of 10 units to set pricing from, and then trying to get a group buy to make pricing more attractive. A small batch of 10 units at a production shop will get the stepchild treatment though.... so cant comment on that yet. I have a call in to see if we can pow-wow on Thursday and try and get all the details nailed down. Having them bid the radiator too.

The OE Ford fans are not a bad option. I just like having the passive cooling flaps and ease of quick removal. I recently lost a crank bolt on a long road trip. Let me tell you how much I wish those bulky S4 fans were out of the way for that job. The way I have the GTS-4 plumbed, both coolers are being used, so couldn't get the fans out, without pulling the lines or risk dumping PS fluid when relocating the reservoir to try and jimmy it out. I guess long story short, if you are fabricating your own fans, try and retain the lower tabs structure, so you just have to remove the two top screws. It will make that next roadside repair much more enjoyable.

longleader

Will this setup fit my US 83'? I could have a have our sheet metel shop do me a favor and make a mounting plate out if you need someone to test fit one ("G Job") Let me know...

Carl Fausett

I guess I am curious too. I don't see how it is any different. Our fits the rad perfectly, leaving just enough room for the hose clips on the front for late-model cars. It does not require any bracketry.

We ARE re-using OEM air intake scoops that we salvage and clean up and re=paint. In one way - then you know they are the right scoops as they are from a 928, but on the other hand, if you can provide new air scoops that might be nice.

I respect your thread - not trying to take it over.

Here is a link to our thread with pictures.
https://rennlist.com/forums/928-foru...l-fan-kit.html

hans14914

Carl,

If it is any help, I will gladly supply you with new intake scoops once I get the molds made. They are slightly different than the stock S4. They are smaller in outside diameter at exactly 3" for ease of use with common tubing options. They also have slightly more cross-sectional area than the factory S4 so that with a symmetrical part, it will work work in either left or right position. Drawings are available if you would like to have a look.

The existing SPAL fan assemblies are nice, and certainly convenient. As mentioned in the first post, I used the larger dual fan assembly from SPAL and quickly found out the second motor was not sealed. I never investigated the smaller fans to see if it used two sealed motor assemblies. If they are indeed both sealed, it may be a good alternative. The only comment I would have is that when I did take a glance at them, they were smaller than the cores "frame" and so would likely need an additional shroud to pull vacuum through the entire core as Porsche originally intended. This was apparently an important part of their cooling design, as you may notice they even specified that the core be offset further forward than the tanks to maximize the amount of negative space behind ht core. The larger fans do have about 16% better flow, and are a bit quieter with the curved blades, but this is likely a negligible factor.

Cost will definitely be higher than that of the offering from 928Motorsports, so if budget is key, I would certainly look in that direction.

Thanks,
Hans