Hey guys,
Made some comprimises to save costs & make the job easier.
Put the thermoswitch into the thermostat housing, in place of the large sensor on top (2 wires). Did this just so we wouldn't have to take radiator out to braze on a fitting. Also where Motortech guys recommended. Thermoswitch is a 92C/87C.
The Mondeo fans are bolted to the radiator with custom brackets.
In the dash there's a rocker switch, one setting is for thermoswitch activated fans, and one is off for water crossings (also has flashing LED for warning light).
Tried to put the water temperature gauge sensor into the block drain plug. The drain plug was exactly the right length, and the same size bolt head, but the pitches were slightly different. I thought they were too close to try and rethread anything.
So I went for one of the alloy blocks that goes in the middle of the top radiator hose and has a thread for the sensor.
Water temp gauge reads 75C crusing down motorway, 80C while idling. I haven't seen the gauge over 80C yet and I haven't seen the fans come on (apart from testing by bypassing the thermoswitch). Can't feel any power increase in driver's seat (not what I did the mod for) but I reckon there would be much less load on the engine. No heavy clutch & fan to spin all the time, and no electrical load from fans under normal conditions.
Engine bay also seems safer to work on without the big spinning wheel of death
.
Can add pics if anyone's interested.
Andy.