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I don't have ac on my car any more and want to fit a elec fan and ditch the viscous

Has anyone done this and use te existing rad fan 25a fuse and relay. Just need a temp fan controller to wire into it I'm assuming?

the existing fan wiring isn't all that suitable for running thermos from memory, as it runs of a little bit higher temp than what you really want.

as for cooling fans though, you are better off with the viscous clutch fan. the power loss of them compared to a thermo is bugger all, and they work just fine. if you are adamant on going thermo though, either go a big single, or a GOOD set of twins that have a shroud already fitted (without a shroud you will cook the engine very quickly, probably in your first drive). something like the thermos from a late model falcon are a good choice (and have been used before by other members on the forum). or some other factory thermos from fwd cars would also do the job

I have a 40mm radiator which has no shroud. The previous owner clipped the blades to get clearance for the thicker radiator

I only want to use the existing wiring for relay and fuse. I want to control it with a separate fan controller

Get yourself a gktech highflow fan & a VL fan clutch. This will be shorter than your current setup, and will work extremely well with a factory fan shroud.

Thermos are a waste of time, and cannot match a clutch fan for airflow.

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