Here's how I plan on doing my e-fan conversion.
I'm going to use the Taurus E-fan for a number of reasons;
1. It comes with it's own shroud that can be modified (cut to fit any Z32 TT rad).
2. It's a 2 speed fan which means that you won't always be drawing a lot of current during normal driving operations.
3. It's CFM rating is equivilent to that of the highest rated Spal fan for the Z32 when on high speed yet draws less current than that of the Spal fan.
4. The cost of a new Taurus fan with shroud is less than 1/4 the cost of the Spal fan alone. If using a Spal fan. one would have to also factor in the cost of a good quality fan shroud like that of the Ash Spec type.
5. Taurus fans are readily available through Rock Auto for dirt cheap -
http://www.rockauto.com/catalog/raframe ... ttype=2181
Taurus E-Fan;
Taurus E-Fan mounted;
Relay Switching/Triggering
I wanted something durable and robust enough to withstand the demans placed on it. I found a Relay Switching mechanism that hs proven itself in use with the Taurus e-fan and many other applications.
http://www.hollisterroad.com/proddetail ... d=MarkVIII
The owner of the company was extremely helpful in answering all of my questions and concerns about the relay and as to what thermosensor I could use with his relay device.
The Hollisterroad Relay has been over-engineered to handle the current demands of the Taurus e-fan and then some. I also got his large gauge wire connectors to integrate the relay to the e-fan wiring harness.
Thermosensor / Thermoswitch
I wanted something that would switch on sooner/earlier and also one that had a two stage switching mechanism so that it would be compliant with the 2 speed e-fan.
The best and least expensive one I found was one made for VW, Audi and Passats.
http://www.carpartsdiscount.com/auto/pa ... 3593=74371
This thermoswitch works as follows;
Low Speed
Turn ON @ 75C
Turn OFF @ 70C
High Speed
Turn ON @ 82C
Turn OFF @ 77C
This seems to be the right temp choices for me as I like to keep the car on the cooler side of the scale.
The nice thing about this thermoswitch is that it allows a step-up from low to high speed and vice versa which will be less of a strain on the electrical current drain of the car. Specialty Z has mentioned that the oem TT alternator is still strong enough to drive an e-fan on it's own but I wanted a bit more security in that department and opted to get a higher output Reman oem alternator to absorb this added current draw. Not to mention it will also be an added bonus to any further high wattage sound system endeavours in the future.
At $9.95 each, you can't go wrong.
Now you will have to get a bung made for this thermosensor and have it welded to your aluminum rad. I decided to get two bungs made at the same time and will have them welded at two distinct different places on the rad. If I feel that the sensor in one place is making the car run too cold or too hot I'll switch my wiring connection to the other thermosensor. It also gives me the luxury of having 2 sensors in place and the ability to switch one for the other if one may prove faulty later on.
These are my plans for a sound and reasonable e-fan set-up that won't break the bank and has the muscle to be just as effective (if not better) than the oem fan set-up. Again, there's the whole debate about the potential power gains by switching to an e-fan set-up which was not my main motivating factor. Having had my original oem fan clutch go faulty on me and being lucky enough to sort a second hand fan clutch, I don't envy the prospect if/when that fan clutch fails. The cost of a new oem replacement fan clutch would pay for more than 3/4 of my e-fan conversion.