FMZIP's Fat Daddio Electric Fan DIY

[BMW540san]

I don't see why you would keep the aux fan if you replace the mechanical fan and clutch with an electric fan. It is redundant and will reduce air flow.

You're forgetting that one of the functions of aux fan is to work with A/C system. Even if the aux fan had nothing to do with A/C system why remove extra layer of defense against overheating.

[fmzip]

Thanks to everyone on this thread for inspiring me to perform this project on my 2002 530i. If someone is just picking up this thread, I made a few additional modifications that might be worth noting:


1. The Derale temp controller has a history of problems. Google it and you'll find the evidence. I learned the hard way after purchasing two units from Summit; Both failed to activate the fan. I'm a pretty competent mechanic and I double checked the wiring many times. I ended up hard wiring the fan via a manual switch until I could source a better controller. I researched and discovered that Hayden has a relatively new electronic fan controller (~$85) that Summit also sells. I purchased it, wired it up, and it works perfectly. Attached are photos of the Hayden part numbers. I also purchased Hayden's in-water temp sensor (sold separately) since I had previously installed the inline radiator hose adapter made by AutoMeter.

2. The in-line radiator hose adapter made by AutoMeter comes in two sizes: 1 1/2" and 1 1/4". This thread recommended the 1 1/2" size yet the ID of the lower radiator hose on my 530i is only 1 1/4". After realizing that the installation of the 1 1/2" size meant stretching the rubber in the hose quite a bit (affecting life??), I decided to purchase the smaller size(AutoMeter part # 2282). I'm satisfied its a better fit that won't stress the hose.

These are the two modifications that I would suggest for this thread. I hope it will save some aggravation if you are about to embark on this project. Thanks again to the original posters for contributing to this thread. I appreciate people willing to share their knowledge and experience.

Below are some photos on my installation. Unlike many who have created somecool enclosures, my install is pretty basic.

Thanks for the addition!

Seems like the Hayden controller would be much easier to implement although it is roughly double the cost of the Derale.

Then again, no need for the box. The Hayden Controller was just introduced this year, something to keep in mind too.

http://www.ratchetandwrench.com/Ratc...an-Controller/

What have you read about the Derale besides the relay not being the best?

https://www.google.com/search?q=Dera..._sm=0&ie=UTF-8


http://www.haydenauto.com/upload/Hay...on-English.pdf

[Redshift]

Does anyone know if the Hayden referenced above shuts down immediately at key-off or if there is a delay (programmable or fixed) built in? I love JimLev's idea of a 2-minute cool down before the fan shuts off and am getting close to doing this upgrade to my newly supercharged touring. I don't want to deal with the mechanical fan any longer.

[Redshift]

Just ordered a fan controller from autocool and will use their "copper sheet" style sensor on TOP of the VF metal coolant pipe to do the sensing. Ordered fan from Summit and cake pan from Amazon. Bring on summer!

[nikatkimber]

*snip*
I don't want to deal with the mechanical fan any longer.

With it getting hotter, I am being reminded constantly of the jet engine trying to fly out the front of my car.

[philly98540]

Another cake pan ftw!

[Redshift]

Perhaps not...I got the pan all trimmed up and ready to install. Quick test fit shows me that the diameter of the round opening on the M62 is different than what's shown on the 6-cyl in this thread

Pics taken with me holding the pan flush with the top of the shroud. You can clearly see the diameters don't match. Not quite sure what to do now.




- - - Updated - - -

Apparently the shroud opening on the M62 is 19 3/4".

So I see they make 20"x2" cake pans but I'm not sure if that would be too big. They are also like $35-38 (yikes).

Any I6 owner want to purchase a pre-made cake pan for your shroud?

[nikatkimber]

Will it set inside the existing shroud? It's unclear from the pictures.

[TerraPhantm]

I might be willing to buy that pan off you. I just need to make sure the e46 m3 shroud is the right size

[pleiades]

Perhaps not...I got the pan all trimmed up and ready to install. Quick test fit shows me that the diameter of the round opening on the M62 is different than what's shown on the 6-cyl in this thread ....

You should be able to find some high-density, adhesive-backed rubber weatherstrip in a suitable thickness and width that would effectively fill that diameter gap and still "look good."

Just a thought with Lowes or Home Depot in mind ....

[philly98540]

Similar fix to an email I just sent you. Always a way.

[Redshift]

Hi everyone - so the diameter of the plastic circular area on my shroud from top to bottom is 19 3/4". Assuming it's a perfect circle, that leaves a 7/8" gap to fill, preferable with something pliable and heat resistant. I'm open to ideas.

I would probably prefer that over any other solution at this time because of cost.

Any thoughts? Something thick and rubbery would seem to be a good fit, don't you think?

(Terra, if this doesn't work out I'll give you the pan - you've done more than the cost of the pan to help me and it would be my pleasure to send it to you at no cost if I don't end up using it)

[philly98540]

Would 1" od black heater hose fit decently? Squeeze it in and then finish off with a bead of black silicone to hold it.

[mapleridge]

amazing work.

[JimLev]

Brian, can you use some spacers to center the pan? Then you will have a smaller gap all around the pan, might make it easier to fill the gap.
Thanks for the controller measurements.

[Redshift]

Would 1" od black heater hose fit decently? Squeeze it in and then finish off with a bead of black silicone to hold it.

It might. Can it be found in straight length so I can make it into a circle?

Brian, can you use some spacers to center the pan? Then you will have a smaller gap all around the pan, might make it easier to fill the gap.
Thanks for the controller measurements.

Probably, but then I'd need to fill that gap between the pan and the shroud. Ideas?

[jstern]

Would 1" od black heater hose fit decently? Squeeze it in and then finish off with a bead of black silicone to hold it.

Brian, can you use some spacers to center the pan? Then you will have a smaller gap all around the pan, might make it easier to fill the gap.
Thanks for the controller measurements.

My local hardware/building supply store sells white plastic blocks (in the fastener section) and also 1" wide aluminum strips in varying thicknesses. You could use either, I think the aluminum would be my choice, to fabricate the spacers and mount the pan with the bolts going through the spacers.

Then use the rubber hose to fill the spaces and seal it in with black RTV on both sides. I bought the RTV in the large cartridges that fit in a caulking gun. I used a similar method on my fan and spread the RTV with an acid brush to make sure the fan was sealed. My fan/shroud assembly is not as pretty as fmzip's but it is solid and has worked fine for over 3 years. You cannot see any of this when it is installed.

Once you start, you will figure out what's best and when you are done, you'll love it.

[Redshift]

I might have to head over to ACE and see what's what. Where'd you guys find the rubber hose? Home improvement or auto parts store?

[jstern]

I might have to head over to ACE and see what's what. Where'd you guys find the rubber hose? Home improvement or auto parts store?

Auto parts store would be the best bet.

[TerraPhantm]

You're forgetting that one of the functions of aux fan is to work with A/C system. Even if the aux fan had nothing to do with A/C system why remove extra layer of defense against overheating.

For whatever it's worth, on all the newer BMW where BMW switched to electric fans, they only 1 run fan. That said, I'm not sure if the fan linked above is powerful enough to replace both.

When I convert to electric, I intend to eliminate the aux fan and run the new fan off the aux fan controller.

[nikatkimber]

Looks like I might be doing this sooner rather than later. My fan shed a blade. Found it when checking the VCGs; sitting next to the oil filter housing. Fortunately the whole thing didn't grenade, and the blade didn't damage anything either, other than a little rip in the underhood insulation.

[fmzip]

Glad to see we have more BAKERS

I say buy the more expensive pan on Amazon, if it doesn't fit return it

[AK_5eries]

Dang, I'm glad you brought up the difference in the M62 Redshift. I also bought everything awhile back and now I have a useless $40 18x2 cake pan. I see Amazon has a 20x2 cake pan by Parrish Magic also around $40.

I'm leaning towards the 20x2 because it would be a cleaner and easier install, but I'll be curious to see what kind of solution you come up with for your current pan.

PS: If anyone is interested in my 18x2, let me know.

[Redshift]

Dang, I'm glad you brought up the difference in the M62 Redshift. I also bought everything awhile back and now I have a useless $40 18x2 cake pan. I see Amazon has a 20x2 cake pan by Parrish Magic also around $40.

I'm leaning towards the 20x2 because it would be a cleaner and easier install, but I'll be curious to see what kind of solution you come up with for your current pan.

PS: If anyone is interested in my 18x2, let me know.

I think I've guinea pigged enough stuff this year. How about you figure this one out and then I'll follow your way?

[BMW540san]

While the baking pan is ingenious idea and probably less work, I like what I did and it's holding up well. Another advantage over pan is that aluminum sheet like mine is bolted to corners of shroud which makes it less likely to flex.
http://www.bimmerforums.com/forum/sh...most-completed