Some things seem to take forever. I started working on these fans in 2021. I got 1 working and the other needed a switch.
I finally found a switch! I bought it!
here is where it goes;
With a struggle I got it in and it would not move.
That's when the struggle began in earnest! I realized that I needed to modify the switch or the contacts to get it to work. I contacted a local electric repair place and made a trip down for ideas. They knew no more than I.
In the process I broke the solder on a wire and resoldered it. I didn't know where it went and soldered it to the nearest free wire.
Then I got into cleaning all the parts up and pulling the brass bush off the shaft and sanding everything so as to give the best chance of working.
I slept on the switch problem and decided that I needed to recess the hole the spring and contact went in. I did that the next day going by trial and error on the depth and multiple fittings to get it to work.
This is the finished product, compare to the above pic and you can see how deeper the spring sits.
I did get the top with the bushing put back together. I used pop rivets and cracked the top. However the bush is held in place now.
Put the thing back together and tried it. Nothing, not even smoke. I was frustrated! My multimeter showed power going in, not coming out, I had power at the brushes, at both ends of the resistor coil. WTF? Then just before bed I saw it. There was no wire connected to one of the plug connectors inside the housing.
Remember that wire I had soldered? I put it in the wrong place. To be sure the next day I opened the good fan and peered inside to verify just where those wires went. Once I knew that I unsoldered my mistake.
Turns out it had to go to one of the brushes and the plug. While the wire I had it to went to the contact/resistor connection.
It was hard to keep the springs/brushes all in place and reassembling this thing about 6 times! Then sliding the switch in and not losing anything.
I did finally get it assembled. I made a stand cause I needed 4 hands to hold things!
I took it out and jumped it off my battery.
It was ALIVE!!!!!
Figuring out where and how to mount them came next. I decided on the inside gutter rail above the rearview mirror. I had to drill holes in the mounts and the gutter and run wires up from a hot wire for my tach. It took time to figure it all out.
I drilled and tapped the holes. I had to wait for connectors for the plugs over the weekend. Once they came in I had it all wired up.
Later that day or the next went out to lunch and tried them out with the engine running. I noticed a drop in speed when both motors were on. I figured my power wire was too small.
So yesterday I ran a larger wire from the fuse box on an unused 30a fuse. I had to undo all the stuff from just a couple of days ago........
Once the wiring was done I plugged it into the fuse box and BLAMMO! the fuse popped, Why? I ran the wire the same!? I unplugged both fans and suspecting a ground put in a new fuse and touched the wire to the fuse and BLAMMO! it went again. I started looking for where I had pinched or peeled the wire. I had put grommets at all the holes and run the wire thru them. I finally found it behind my gps mount at the bottom of the windscreen. I wrapped it with electrical tape and made the opening larger for it to not get pinched again.
Put in a fresh 30a fuse and touched the wire. All was quiet! I went inside and threw the switches. Everything worked! 2 speeds on both fans! No smoke! I put a ziptie on the wire by the fuse box and called it good!
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