Another Cracked Fan and Fan Shroud

[ksluna]

Hi guys,

I have a 89 911 and my mechanic let me know that there are cracks in on the Fan and Fan shroud.

There are a couple thin cracks on both the shroud and fan.

Pic: https://imgur.com/a/dyEovta

After some research and reaching out to Ben (mb911) it seems like this is just too much work to weld or repair.

It seems like my only option is to cough up $1200 for a new aluminum fan and fan shroud.

Just wondering, is this an age thing? Has most other owners replaced these parts or are a lot of guys running on their original fans/shrouds?


Can anyone recommend or provide reviews for the upgraded aluminum ones offered by our vendors? They seem to have sub-par reviews.

Cooling Fans:

• EPS aluminum fan - $500
  
• Aftermarket Aluminum Cooling Fan - $400

Shrouds

• EPS Fan Shroud (Is this aluminum?) - $704
  
• Aftermarket aluminum fan shroud - $825

Can anyone point me in the right direction? Seems like there is quite a large price difference in the two.

[LUFTKUL]

I bought an EPS shroud for my '84 from the big vendor in Miami and it worked just fine with no quality issues other than you must coat it with something before installing. Even just some clear coat out of a can would get the job done. The raw finish surface corroded almost immediately.

[mepstein]

DC Auto was carrying the carpoint brand. Not sure what they have in stock but prices seemed reasonable.

[mepstein]

[mepstein]

[gtc]

It appears that new fans are available at Sunset for $389

[mb911]

I don't see issues with the cracks in your picture.. Most can be fixed for under 200

[KTL]

The issue is that a lot of wrenchers crank the heck out of the fan strap bolt and crack the housing. But there's a lot of them like this and you don't hear of the shroud coming apart. My '86 shroud is a typical cracked Carrera piece and who knows how long it's been like that. Car has been in the family of friends since 1999. I'll still send it to Ben to weld it up. But if I did nothing with it, it would be fine.

I agree that picture of the fan doesn't appear to be cracking. It looks like an uneven surface defect left from the metal casting process. I would roughen it with a file or carbide burr bit and polish it out.

[ksluna]

Originally Posted by mb911

I don't see issues with the cracks in your picture.. Most can be fixed for under 200

Hey Ben, I emailed you late last year with these same pics and you told me it seemed like a lot of work. I can try and provide some better photos to get another quote.

Here is another pic: https://imgur.com/a/hAm3pSl

Originally Posted by KTL

The issue is that a lot of wrenchers crank the heck out of the fan strap bolt and crack the housing. But there's a lot of them like this and you don't hear of the shroud coming apart. My '86 shroud is a typical cracked Carrera piece and who knows how long it's been like that. Car has been in the family of friends since 1999. I'll still send it to Ben to weld it up. But if I did nothing with it, it would be fine.

I agree that picture of the fan doesn't appear to be cracking. It looks like an uneven surface defect left from the metal casting process. I would roughen it with a file or carbide burr bit and polish it out.

I don't think the fan is cracked, I just think the shroud is cracked - https://imgur.com/a/hAm3pSl

So are you saying that there are a lot of cracked shrouds there and that this part won't typically break? I took it to a mechanic and he said this would be catastrophic if it broke and I should replace it immediately (and then quoted me $2,000 to fix it)

[KTL]

Yes I believe there a lot of cracked shrouds in that area. My Carrera shroud is cracked in apparently the same spot- 9 o’clock hub support base where it connects with outer ring. The Carrera shroud is notorious for cracking. But all we ever hear about is the cracking. I’ve yet to hear a mention of the fan and alternator coming free of the shroud. Not saying it’s never happened (probably has in sustained high rpm use like racing) I’m just saying it’s something that rarely ever happens. That said, these cars are only getting older and things are going to be breaking like we’ve rarely ever seen. Nothing lasts forever despite how well built/designed these cars were

$2,000 is a bit nuts. Mechanic must have been quoting you the new price of a shroud from European Parts Solution (EPS) since the original part from Porsche is discontinued. Current price from EPS via Vert-ex in FL for a Carrera shroud is $789, which is a big kick in the junk. Still, another $1,200 in labor to replace the shroud is pretty steep. It’s quite easy to remove the shroud. Tough part is removing the plastic air guide behind the alternator which then gives you access to the wiring connected to the alternator. Only reason it’s tough is because access is tight and the wiring is short. Then you have to knock the alternator out of the shroud- evenly strike the shroud on some wood blocks which lets gravity “press” the alternator out of the shroud hub

[ksluna]

Thanks, KTL. I don't race my car, and it certainly doesn't spend a lot of time at sustained RPM. I think I will leave it for now. The mechanic sure did make it seem like it would blow up my engine if it were to happen.

He quoted me that price for the shroud and 400 for the fan.

I think you are right in your first paragraph though. I read a bunch of threads and not once did I see a case of the shroud/fan completely breaking. Just that it was cracked and owners replacing it with aluminum aftermarket or having a Mg welder repair it.

[pmax]

Fan looks fine. Really your call to replace the fan casing. If the fan does break a fin, I do think the damage should be self contained given the casing and the fiberglass shrouds protecting the sensitive areas. But then, it could hit a fuel hose.

Don't the pros always mark up parts prices above what you can get from any of the online places ?
The parts at $825+$400+shipping+markup and 2-3 hrs labor, that's about $2K which is nothing in the world of Porsche maintenance. Been there, done that.

[Flojo]

My fan shroud had a few beginning cracs I noticed prior restauration.
I dremeld the cracks, made tiny relief bores at the cracks ends and JB welded them.
also JB welded as reinforcement at every connection spot I believed to be some kind of tension force.

turned out very nice and was no issue for ceracoating afterwards.

[KTL]

Well there you go. $400 for the fan is needless in my opinion. Even if the fan were to have a damaged blade or two I wouldn’t replace it. There’s a ton of fans spinning around in these cars with blade tips that are chipped and/or cracked. Usually happens because someone foolishly jams something in between the blades to hold the fan still so the nut can be tightened. They do the jam routine because a hook spanner isn’t on hand to properly counter hold the fan pulley

Even with the damaged blades they aren’t coming apart. I just re-shape damage with a fine cut file to smooth it out. Probably should balance the fan to account for the missing blade material but if it’s minimal they don’t seem to vibrate excessively and harm the alternator bearings

I recognize where the cost is coming from to make it $2k. I just think it’s excessive because this is a fairly easy DIY for most 911 owners. Nothing highly technical about the removal and replacement of the shroud. Toughest part is coaxing the fan off the alternator shaft (sometimes a bit of surface rust prevents fan from easily sliding off) and getting to the small nuts which secure the air guide behind the shroud. The woodruff key in the shaft can also be an annoyance if it won’t stay in place when you slide the fan back in place. Also a good idea to put a light swab of oil on the alternator shaft to make future fan removal easier

[grizzfan]

Well perhaps you do need a new fan and shroud, but maybe you don't.

I had a very chewed up 11 vane fan and sent it to a guy with last name Moshagen. He's the guru of fans, believe me. I've looked through all my receipts and cannot find the contact info - perhaps someone on this thread has info. If it can be repaired he can do it.

Tom

[911pcars]

Mark Motshagen, mots356@yahoo.com in Orange Co., CA

[Jonny H]

If you fit our 175A alternator, it is the same length as the early pre ‘74 unit so you can use the early fan housing. This is stronger as it does not have as much material machined away.