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New cai is a tight fit due to the tb spacer. It was a freebie from a friend so im thinking i might take it off since the intake is now sitting funny but i kinda like how it looks with all the red.
 

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Started work on my fan shroud last night for my new slim radiator fan. Total thickness will be between 1/2" and 3/4". I bent up the edges to be 1/2" with a bead roll, and then I will also put some vacuum line down all the edges to protect it from hurting the radiator. its only 20 gauge aluminum, but it still has a lot of rigidity with the bends at all the corners. I knew it would stiffen up, but I didn't realize this much lol. Still need to cut the center hole out for the fan, and then I will probably flare that edge as well to give a little bit more 3d support and help direct the air towards the fan.

The shroud measures 20" x 16". My core size is 24"x15". The fan is a "16inch" fan, but the blades are only 15".

Total core size area = 360sqin. The fan area is 176.6sqin, roughly 49% of the total core size. With the shroud, I now cover roughly 85% of the radiator area, so a big improvement. For those wondering, I couldn't do the full radiator because my cold side intercooler piping runs right up against the now thicker radiator, so I had to miss that part of the area due to clearance. It still has enough room between the piping and the radiator for air to flow and no contact, but not enough room for the 3/4" total thickness shroud.

20gauge aluminumm - $20 off of amazon for a 24"x36" piece (only needed about half of it for the shroud). Hit it till it fits! I just marked out all my lines, clamped it to some wood I had, and then just kept hitting the edge till I got the bend I wanted.



All edges done:


Figured out my placement of the fan on the car, marked it up and I will cut this out tonight/tomorrow


What it will look like on the car:
 

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Getting further with my fan shroud, hopefully will finish it up after some family stuff tonight.

Cut the hole out with a jig saw (woo new tool) and a metal blade, then smoothed it out with some dremmel tools. Also bent up the edge of it to add some 3d shape as well as help direct air flow to the fan blades. Added vacuum hose over the end of the double bend edges to add a little insulation. Finally, mounted up the fan using my rivnuts (god I love that tool).





Here you can see the bent edge for the fan blades and directing the airflow:


Gonna hopefully get all the brackets done tonight that way the system will be ready to bolt into the car. Gonna have to slightly rework the metal coolant lines, have about 1/2" to cut out and reweld on each one since the radiator isn't quite as wide as the stock radiator.
 

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Got most of the radiator stuff done last night.

Got the brackets finished up for the fan shroud:


Just used some 16gauge aluminum, my hammer, vice, drill and rivnuts to make it all fit. Puts a nice compression on the shroud so that the rubber is loaded, but not so tight as to crush anything. Should keep it in place pretty easily. I used 1/8" rivets to mount the brackets to the radiator (on the mounting plates that the radiator comes with) and then put rivnuts on the brackets for easy attachement/removal.





Then I decided to see how it all finally fit in there (I had fit before, but it was mostly holding by hand, so it was nice to see it all in there by itself. Sorry for the bad photos, lighting is an issue in my garage lol).



Exhaust is a bit closer than I wanted, adn I could maybe shift it over a bit, but I like where the fan motor is in relation to all the piping, so I might go ahead and run it like this. With all the air running by the plastic it should be OK, and I also have a bunch of heat wrap to put on the exhaust so before I run it that dump pipe will be wrapped. Minimum spacing is about half inch between the flex joint and the very edge of the fan support.





And finally I started looking at the coolant lines. Mine are stainless pipes with reinforced chemically resistant couplers on either end, and I was worried I was going to have to cut down some sections due to the decreased width of this radiator compared to stock. Luckily I was able to get everything to fit by just trimming off some excess silicone from the coupler, so everything "technically" fits. Its getting pretty tight in there lol.



Gonna pull the exhaust off so that I can clean it and the engine bay (coolant residue still on a lot of the engine) and wrap the exhaust pipes, then I should be all done with this fiasco.
 

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Stared working on replacing the bumper support in the car since I have everything out of the way that needs to be removed anyways. The bumper support has been bent since I have owned the car by the previous owner, and one of those things I always wanted to replace but was always just buried in the car to get to.

Here is a picture showing before how they were slightly bent (passenger side is not as bad, top is good, only need to pull the bottom out a little bit with a slide hammer).



I had to notch the stock bumper in order to get the intercooler to fit because of the bends in the support, so I decided it was time that I go ahead and replace this mess. Ordered parts off of AM, about $20 a side. The only issue with them is that the holes do not come tapped for bolts, so you will either need to tap the threads like I did or just get a slightly smaller bolt to run through it and then put a nut on the back end. The load will get transferred to the bumper and bumper support, so a typical bolt should be fine.

I looked online a lot to try to find out how to replace these and couldn't find anything. Was a little nervous about doing it, but then I just said F*** it, its not like I can make it worse. There are a lot of spot welds holding this bad boy together. 6 on the front face, and then 4 inside that connect the frame, rad support and bumper support/absorber. You gotta pick and choose your spot welds because there are some others in there that are only for the frame to bumper support.

Fast forward 2hrs of battling with my 2lb sledge, sawzall, spot weld cutter, and grinder and I end up with the mess below:





The "Void"


New Fitment:


I am debating on how I want to put it in. I could go for rewelding part of it, but I am thinking I might just bolt it in to the frame with some 3/8" bolts since I can get a wrench in there, and then weld the face. That should be more than strong enough since I am probably also going to be putting in a tow strap on the bumper beam bolts.

Now that everything is apart and reworked I am finally almost done with this ordeal. I have some new exhaust heat wrap, so I will pull that off real quick and wash the engine bay from the coolant residue, wrap the exhaust, and then finally everything goes into reassembly. Should be running by tomorrow.
 

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...For those wondering, I couldn't do the full radiator because my cold side intercooler piping runs right up against the now thicker radiator, so I had to miss that part of the area due to clearance. It still has enough room between the piping and the radiator for air to flow and no contact, but not enough room for the 3/4" total thickness shroud.
:thumb:
 

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checked my passenger side manifold that i just replaced last year with an oem part. cracked on the same spot again thanks to that ac drip :/....ok so time to order a set of stainless steel shortys. question has anyone thought of a good way to divert that drip since its so close to the manifold?
 

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Build a little system that diverts it away from the header. I forget how to do it but i remember someone putting something together for that specific problem. I found longtubes for my car for $20 when mine cracked so i didn't have to deal with it.
 

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Got the bumper support welded on this weekend (with the addition of an awesome burn on my arm from the welding torch, doh). Not the prettiest welding, but should hold for what I need it to do.





Painted that black as well as some miscellaneous brackets and some spots I missed when I originally sprayed the engine bay black.

Pushed the car outside and used a 1 gallon spray bottle to clean up the engine bay from any coolant residue (wish I had a house with a hose, but this worked out pretty well for a $15 spray bottle and cleaned it up enough).

spraying engine bay (damn you white balance!)


Spraying down other parts/piping


Started getting parts back onto the car. Turbo and pre turbo exhaust is in that I wrapped up with some DEI heat wrap, ac condenser and the powersteering cooler are in, radiator, shroud and lower coolant line are in minus the top brackets, and the intercooler bracket is back in.

Gonna get the rest back on tonight, which includes the fan, turbo dump, air filter, upper coolant pipe, intercooler piping, vacuum line for the BOV, connect up my o2 sensors, wideband, and front bumper/headlight panel. Hopefully get to the point where I can start it again tonight.
 

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got the flowmaster 10s but on with some temp tubing for the mid pipe. gonna be taking off the cats and then adding in an x pipe shortly.



also did my fuel filter today as well since i hit 130k miles. figured it was time
 

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got all the necessary bits buttoned up on the mustang and got it running after putting in some new coolant.


I also noted that the front bumper has a very minimal contact to the intercooler, so I started notching that part out. I cut out part of the steel box and bent it to form a triangle instead, this way it won't contact the intercooler or block any of the vents, it should allow plenty of air to pass through the intercooler instead of blocking about 1/3 of it. I will post pictures of this tonight.
 

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just order a bama chip since i've been wanting to A) fix my cel from where my rear o2's are cut off and B) get some firmer shift points on my auto. i did a lot of looking online but can't find alot of v6 reviews. anyone here run one?
 
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