I received the new set of cast aluminum valve covers for my 79' and a new brake booster kit for the project. That means I'll have the original booster, brackets and M/C available for sale if anyone needs.
Took a ride in the 79' today and hit a nice size bump which caused my flex a lite fan to shed three blades on the right side fan.... So now I have to either find a replacement blade or install the countour fan that was meant for the project and hit the junkyard for another one. One step foward and ten steps back, gotta love jeeps.
I'm going to put the contour fan in the 79'. I need to get it done by thursday because I have to get the 79' smogged and re-register it. I do have some questions though.
1. The flex a lite unit was very light weight and the contour assembly is much heavier. I'm concerned about damage to the radiator and fan assembly by installing it with those plastic radiator zip tie things. Like if I hit another bump...hard. Has anyone installed one in their CJ who can offer up any feedback on using the zip tie's? Any failures with these things? I made an aluminum shroud for the flex a lite which used the radiator mountings bolts only so I didnt have to use the zip ties.
2. I have the original fan harness off the contour but it is dried up, cracked and a fire waiting to happen. What are these connectors and do I need them? I have searched through the forum and the write ups all have DIY wiring jobs. Is it worth trying to save this harness and connectors?
3. When using the FAL controller, is the temp sender switch that goes into the back of the thermostat housing on the 6 cyl the same thread as the one on the back of my 401's thermostat housing? If so I'm gonna buy one and use that. But for right now I just need to wire it up so it works with an on off switch on my dash so I can atleast get it smogged.
Ok, I got the fan mounted with the zip tie things in about 20 minutes. I cut the brackets off and filed down the sharp edges. This was by far the easiest swap, it literally dropped right into place.
Now onto the wiring. I went to Autozone and asked for the FAL controller and the guy says "Flex a lite, is that a brand? What vehicle, I need to look it up" I wound up walking to the back shelf and looking through all of their cooling parts. Needless to say all they had was the zip ties. This led me to O'reilly's, Pep boys, and Napa with negative results.
So my plan for the time being is (sorry no diagram) to run power from the battery via 8 gauge wire to a 6 circuit fuse panel (30 amps per circuit) on the fender. Then run power to a seperate relay for each fan from the fuse panel to each relay with 10 gauge wire. Then 10 gauge out to each fan and grounds. I have an old bulb type adjustable temp switch that I will stick in the radiator and use to switch the relays which will be connected to an on/off dash switch. This is just to get me through until I can smog it and then I can find a FAL controller online or something.
'Black Betty' uses a single 18" flex a lite in a shroud I had to modify. Originally the fan was mounted through the radiator fins tightly with the supplied zip ties, later I found heavier duty ones. However over time the torque of the fan began to abrade the coolant tubes in the radiator causing leaks. I addressed this by fabbing up some strap mounts to the shroud~and a new three row radiator.
The parts shop that stocks part for Skylab II will not have parts for our year/model of Jeep
We cannot accurately judge the trajectory of a speeding critter (cat, dog, sasquatch)
Record heat waves and floods only occur when we visit that area
I used a total of 8 of those zip tie things, it's on there real good. I tried to make a rubber seal along the edge of the fan housing to cushion the radiator tubes by cutting 6 feet of 3/8th's rubber fuel line down the center and slipping on the housing edge but it interfered with the installation because the fan is such a direct fit without it. I had to work dayshift today so I didn't get to wire it up yet.
I got a quote to media blast the tub, hood, windshield frame and cage..... $1000.00. Guess I'll be stocking up on strip discs and stripping it in my driveway. I was trying to avoid the mess but $1000.00 is f'n crazy.
Tylerzap & Jtubbe0109, thanks for looking. I hope to make some more progress on the actual build (83') and stop messing with the 79'. I have about an hour today that I can use to wire up the contour fan so I can go get that CJ smogged and registered.
THE CONTOUR DUAL FAN SWAP IS BY FAR THE EASIEST AND MOST EFFECTIVE COOLING UPGRADE I HAVE EVER DONE!!!!!!!!!
The install went as follows:
8 gauge power from Battery + terminal to a 6 circuit (each circuit rated at 30amps) panel on right side inner fender. I used two of the 6 circuits and ran 30amp fused power to two Bosch sealed relays (pulled with the bracket from a 97' caddy) each having their own 30 amp fused circuit. Then each fan was wired up with their own dedicated relay with 10 gauge power from their relay and 10 gauge grounds that run back to the Battery - terminal. I have an on/off switch mounted on my dash that provides power to my old school fan control switch (bulb mounted in radiator type) that controls the fan relays on/off. All connections were sealed with heat shrink tubing and covered in the plastic loom.
I am very impressed (that my jeep didn't burn to the ground ) with:
#1 - The fit - After cutting off the brackets the fan drops right into the radiator between the tanks and completely covers the entire cooling surface of the tubes/fins.
#2 - The flow - The amount of airflow that these fans pull feels like nearly double what the Flex a Lite unit was pulling.
#3 - The function - The entire system works very well and I don't even have a fancy controller.
#4 - The cost - $50 for the fan at the yard + $30 for miscellaneous electrical items and wire that I needed.
#5 - The ease of install - This was a VERY EASY install, thanks to all of those great write ups and threads on here.
I drove it all over today with no issues, both fans kick on 'high' at the same time and my alternator can keep up with them. And to top it off, my 401 passed smog on its own today .
Here's some video, (The wiring for the fan is all neat but the rest under my hood needs to be cleaned up a bit, it's on the to do list):
Awesome. Those Contour fans really are a perfect match.
Hey Coiz, quick question for you about those Ford Factory connectors in the contour wiring harness.... are they resistors or something? It works perfectly without them but I'm just curious for when I install the one on my project.
The resistor bolts to the shroud in the lower corner so it is in the main air stream. It is the wound spring inside the metal cover with all the holes in it in the background on the right side of the second resistor picture. You only need this if you are wanting to run the fan(s) at reduced speed. Without it they will obviously run at full speed. The other component you pictured, I believe it had purple wires going to it, is used for the Contour A/C system so you can just remove it since you don't need it for anything.
Mike My build thread
1979 CJ7, FI 5.0L Ford, NP435, D300, Full floated D44 Detroit, D30 Detroit EZ Locker.