DIY - upgrade Trust intercooler fan

[Joyride]

The stock fan is small. I think around 6 inches.

Now try to put in a 10 inches fan which was one of the long pending project i wanted to do.

here are some of the photos to share during my diy.

Took out stock fan and intercooler.

hook on the 'new' fan to see the right position and fitting.

<a href="http://www.flickr.com/photos/min-min/5571392418/" title="IMAG0490 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5260/5571392418_cf1370e31f_m.jpg" width="143" height="240" alt="IMAG0490" /></a>

After some thought, i decided to tilt the fan slightly upward so that it will blow upward so that hot air can easier get out from the engine bay thru the bonnet, i hope...

Then i begin to measure the brackets size needed and start fabricate.

<a href="http://www.flickr.com/photos/min-min/5570830059/" title="IMAG0497 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5254/5570830059_a286d932ec.jpg" width="500" height="299" alt="IMAG0497" /></a>

---------- Post added at 10:58 PM ---------- 6 hour anti-bump limit - Previous post was at 10:49 PM ----------

Oh, forgot to mention, the Trust intercooler can be dismantle and take out from the top. It do not need to dismantle the alternator and take out from the bottom as mentioned by some mechanic. you have to be patient and twist around the IC to get it out. The engine oil dip stick gotta take out to give the way.

 

[DanzEterna]

how bout the wiring, u connect to radiator fan is it?

 

[Joyride]

how bout the wiring, u connect to radiator fan is it?

Oh, SW20 has it engine room fan wiring, it activate with the temperature sensor that located at the bonnet. Once reached certain temperature, the fan will run. I will use back the same wiring source to add a relay as this fan might take more power then the stock.

 

[dr_snape_79]

Good.. Can try.

 

[Joyride]

DIY continue... now need to extend the shroud to cover up the gap..


Now start construct the fan shroud, measure the plate required... place the fan shroud on the floor use the floor as base guide...

<a href="http://www.flickr.com/photos/min-min/5585471816/" title="IMAG0511 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5060/5585471816_a9c547f48b.jpg" width="299" height="500" alt="IMAG0511"></a>

then cut out the plate and rap around the original fan shroud to get detail measurements.

<a href="http://www.flickr.com/photos/min-min/5584841929/" title="IMAG0513 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5252/5584841929_16261b054a.jpg" width="299" height="500" alt="IMAG0513"></a>

<a href="http://www.flickr.com/photos/min-min/5585472198/" title="IMAG0514 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5108/5585472198_b253351dfe.jpg" width="300" height="500" alt="IMAG0514"></a>

<a href="http://www.flickr.com/photos/min-min/5584767415/" title="IMAG0515 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5051/5584767415_1f45d2bc61.jpg" width="300" height="500" alt="IMAG0515"></a>

<a href="http://www.flickr.com/photos/min-min/5584766455/" title="IMAG0518 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5101/5584766455_54caed7958.jpg" width="500" height="300" alt="IMAG0518"></a>


The cut off the plate to fit the original fan shroud.

finished extended shroud

<a href="http://www.flickr.com/photos/min-min/5584766859/" title="IMAG0516 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5147/5584766859_a8b1ed4872.jpg" width="300" height="500" alt="IMAG0516"></a>

---------- Post added at 11:17 PM ---------- 6 hour anti-bump limit - Previous post was at 11:06 PM ----------

now, start rivet the extend shroud to the ori shroud..

--> drill a hole the fit to the rivet. the hole must be fit tight to the rivet, otherwise it will not hold the extend shroud.

<a href="http://www.flickr.com/photos/min-min/5584765227/" title="IMAG0519 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5172/5584765227_bb37a13034.jpg" width="300" height="500" alt="IMAG0519"></a>

<a href="http://www.flickr.com/photos/min-min/5584765105/" title="IMAG0520 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5016/5584765105_ac9cfbabf4.jpg" width="500" height="300" alt="IMAG0520"></a>

use a bigger drill to drill off the excess steel with hand..

<a href="http://www.flickr.com/photos/min-min/5584756485/" title="IMAG0524 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5310/5584756485_eca084f618.jpg" width="300" height="500" alt="IMAG0524"></a>

<a href="http://www.flickr.com/photos/min-min/5585350228/" title="IMAG0521 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5148/5585350228_30d33fb254.jpg" width="300" height="500" alt="IMAG0521"></a>

---------- Post added at 11:21 PM ---------- 6 hour anti-bump limit - Previous post was at 11:17 PM ----------

The extended shroud plate is quite thin... so i hammer down the tagged rivet to further strengthen it...

<a href="http://www.flickr.com/photos/min-min/5584746067/" title="IMAG0528 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5185/5584746067_39bc34b79e.jpg" width="300" height="500" alt="IMAG0528"></a>

like this more firm.

<a href="http://www.flickr.com/photos/min-min/5584745679/" title="IMAG0529 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5229/5584745679_dbc524d461.jpg" width="500" height="300" alt="IMAG0529"></a>

---------- Post added at 11:26 PM ---------- 6 hour anti-bump limit - Previous post was at 11:21 PM ----------

rivet around the shroud to hold it extended part. make sure the extended shroud in the right position before you drill and rivet. again u can use the floor as based to guide the extend shroud when drilling..

finished rivet shroud.

<a href="http://www.flickr.com/photos/min-min/5585336948/" title="IMAG0530 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5299/5585336948_d580a935cc.jpg" width="300" height="500" alt="IMAG0530"></a>

the fan is really oversize... so after put on the intercooler... cut off small part as shown below inorder to let the fan shroud to sit properly on the intercooler.

<a href="http://www.flickr.com/photos/min-min/5585336590/" title="IMAG0531 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5304/5585336590_b87be2518d.jpg" width="300" height="500" alt="IMAG0531"></a>

---------- Post added at 11:34 PM ---------- 6 hour anti-bump limit - Previous post was at 11:26 PM ----------

there are still 2 more area need to cover up at the side of the intercooler...

cut off 2 more steel plate to over it up... for this 2 small plate, i fold the plate in two so that it more firm and strong.

<a href="http://www.flickr.com/photos/min-min/5585333736/" title="IMAG0532 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5225/5585333736_c8c3606e33.jpg" width="300" height="500" alt="IMAG0532"></a>

<a href="http://www.flickr.com/photos/min-min/5584742009/" title="IMAG0533 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5022/5584742009_9736c5cf13.jpg" width="300" height="500" alt="IMAG0533"></a>

place the plate to the position and mark hold for drilling. i use back the same hole that hold the fan shroud to tie the plate.

<a href="http://www.flickr.com/photos/min-min/5585300460/" title="IMAG0534 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5303/5585300460_7820e0a87c.jpg" width="300" height="500" alt="IMAG0534"></a>

then cut off the excess parts so that it easier to install later..

<a href="http://www.flickr.com/photos/min-min/5584708873/" title="IMAG0535 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5293/5584708873_6bd43639a4.jpg" width="500" height="300" alt="IMAG0535"></a>

 

[Joyride]

completed fan shroud.

<a href="http://www.flickr.com/photos/min-min/5584681871/" title="IMAG0537 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5260/5584681871_8281f0f474.jpg" width="500" height="300" alt="IMAG0537"></a>

<a href="http://www.flickr.com/photos/min-min/5585273986/" title="IMAG0538 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5307/5585273986_14f0ed8668.jpg" width="500" height="300" alt="IMAG0538"></a>

spray to mat black

<a href="http://www.flickr.com/photos/min-min/5585272824/" title="IMAG0539 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5184/5585272824_3cb1f53987.jpg" width="300" height="500" alt="IMAG0539"></a>

Not so good looking but it does what it suppose to...

<a href="http://www.flickr.com/photos/min-min/5584680985/" title="IMAG0541 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5021/5584680985_f3a785d5b9.jpg" width="500" height="300" alt="IMAG0541"></a>

different of the stock fan and the upgraded one..
<a href="http://www.flickr.com/photos/min-min/5584680575/" title="IMAG0544 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5135/5584680575_1839e7ff93.jpg" width="300" height="500" alt="IMAG0544"></a>
<a href="http://www.flickr.com/photos/min-min/5585271570/" title="IMAG0543 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5110/5585271570_2666ee2e47.jpg" width="300" height="500" alt="IMAG0543"></a>

<a href="http://www.flickr.com/photos/min-min/5585270510/" title="IMAG0546 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5266/5585270510_ed49024b68.jpg" width="300" height="500" alt="IMAG0546"></a>


installed into the engine bay. it fan shroud was designed abit too big(high). it is very difficult to get it into the position. this is becuase I tried to make the fan far away from the Ic so that the air can come in more balance thru the IC as the middle part (fan motor) have no suction power.


<a href="http://www.flickr.com/photos/min-min/5585231220/" title="IMAG0547 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5060/5585231220_695a2a9264.jpg" width="300" height="500" alt="IMAG0547"></a>