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Fan & Fan Housing Cracked: Options

So I separated my fan and housing to inspect them before sending them out to get refinished and I found 1 crack in the housing and 1 delaminated fan blade trailing edge.







I believe these are my options, ranked from $ to $$$:

1. Weld repair on fan and housing (possibly $-$$).

Downsides are possible re-cracking in other areas?

2. Used fan and housing with no cracks (guessing at least $$).

Downsides? If the fan strap is not over-torqued and the fan blades don't ingest any foreign objects is there a risk either could crack in the future?

3. New aluminum housing and fan from aftermarket supplier such as Vertex ($$-$$$).

Downsides are non-OE appearance, some possible issues with the timing marks per this thread and this thread, and a tad heavier. Possible issues with alternator fitment.

4. New OE fan and housing ($$$$ if I can find them).

Did I cover them all or does anyone have anymore nuggets of wisdom on this common issue?

So much for blinging out my fan on my ongoing rebuild.

Thanks in advance.
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Old 12-13-2017, 03:55 PM
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My suggestion would be to speak with Mark Motshagen (mots356@yahoo.com) - he can repair them if possible, otherwise can get you a new housing and refinish the housing and your fan to match and have a very close to OEM stock appearance. He did my '85 and I was very happy with the service, results and price. The whole thing including the new housing cost me $800. My fan was OK, but the housing was pretty bad and opted to go for a new one.





Good luck,
Bill
Old 12-13-2017, 04:02 PM
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Bill,

I did have a quick chat with Mark prior to disassembling and discovering the damage. He said welding doesnt work well and that if the fan blade damage is very minimal he might be able to get away with re-dressing the damaged edges. I guess I will have to take the parts to him to make the final call.

Did he source you a used un-cracked housing or a brand new one?
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Old 12-13-2017, 04:09 PM
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If your not looking for a permanent concours solution, you could get jb weld aluminum putty and gusset both sides after sanding. Will hold for a long time and the putty is the same color as aged magnesium...

This is not the same as jb weld...
Old 12-13-2017, 04:53 PM
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We weld repair fans and housings that are in far worse shape. Shoot me an email if interested.
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Old 12-13-2017, 06:05 PM
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I found a new one listed here: Magnesium fan-housing replacement.

These housings are sold by CarPoint in Germany.

fan housing alternator 911 3,2 Carrera 3,3 Turbo

Edit - New Porsche fans 930-106-012-01 available.

Last edited by HaroldMHedge; 12-13-2017 at 07:38 PM..
Old 12-13-2017, 07:09 PM
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Quote:
Originally Posted by 2jmotorsports View Post
Bill,

I did have a quick chat with Mark prior to disassembling and discovering the damage. He said welding doesnt work well and that if the fan blade damage is very minimal he might be able to get away with re-dressing the damaged edges. I guess I will have to take the parts to him to make the final call.

Did he source you a used un-cracked housing or a brand new one?
Mark sourced a brand new one. I don't recall the manufacturer, but said it was made it Germany. There is a tapped hole in a boss where the coil would mount on an early car, he filled the hole and coated so it does not show. The part number is correct for my '85, but that mounting boss would give it away if I were building a show car.

Bill
Old 12-13-2017, 07:18 PM
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Argh. So this crack on the housing "vane" is present on both sides:



Also there are 2 more cracks that are visible from the OD:





This is all the damage present. Doesnt seem catastrophic so maybe it can be saved through welding.

Harold, thanks for the link to the new German unit.

So my fan is a 102.0R and none of the reference numbers on the german CarPoint unit match up. Closest is a 102.2R. Any idea where I could cross check the part number compatibility?
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Old 12-13-2017, 07:47 PM
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This thread reviews the difference in the Fan housings.

Quote:
Originally Posted by tom1394racing View Post
Here's the Fan/Housing/Alternator data in a better format

Old 12-13-2017, 09:46 PM
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Quote:
Originally Posted by RarlyL8 View Post
We weld repair fans and housings that are in far worse shape. Shoot me an email if interested.
Aren't many of the housing magnesium? Do you guys have the ability to weld those also?

Bo
Old 12-14-2017, 06:34 AM
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Thanks Harold! Time to deep dive into part number compatibility.
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Old 12-14-2017, 08:49 AM
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You can weld magnesium (MB911 does a great job) but what I have found is once the mag fan housing starts to crack and you repair it, you will just be chasing future cracks. The mag seems to fatigue. I think the chips in the fan are worth repairing since they are different than a fatigue crack. When the mag housing on my 3.2 cracked, I purchased an aluminum replacement. My gut feeling is the mag fan housings are too thin. I think the aluminum ones will hold up better.
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Old 12-14-2017, 11:29 AM
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Quote:
Originally Posted by HaroldMHedge View Post
I found a new one listed here: Magnesium fan-housing replacement.

These housings are sold by CarPoint in Germany.

fan housing alternator 911 3,2 Carrera 3,3 Turbo

Edit - New Porsche fans 930-106-012-01 available.
I went that route and purchased the new magnesium part from Carpoint delivered to CA in 2 days for around $500. Great part, with perfect fit of a Valeo/Porsche 90A alternator.The Al replacement is 3-4X heavier, far more expensive, and the fit (I'm told) is not so good.

Last edited by adias; 12-14-2017 at 03:03 PM..
Old 12-14-2017, 03:01 PM
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My fan was fine but the housing was worst than yours. I ended up getting an al one from vertex, didnt know about this german site. It fits but the cavity for the alternator needed alittle grinding to sit the alternator
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Old 12-14-2017, 03:20 PM
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I have only had 1 fan I couldn't fix.. The fan rings are repairable. I do a couple a week.. Gonna start advertising. To my knowledge no one else out there is actually welding them to repair them. The majority of the restoration shops are epoxy and painting..

I actually weld them and fix them correctly.. There maybe a few others that do I am just not familiar with them..

I repaired hundreds of them for members here including many engine builders.
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Old 12-14-2017, 03:44 PM
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Jose... Sonnen Porsche may have OEM fan and housing for $765 total. I got a few fans from them. All good.

Am using aluminum housing from Vertex. Think it was $565 when I got it. Just looked at their site... they're now getting $949. for it.

I've not heard about magnesium being repairable with any heat media. It ignites (and there's no putting it out as far as I know. Maybe Halon would kill it due to there being a lack of oxygen to burn.)
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Old 12-14-2017, 04:38 PM
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Quote:
Originally Posted by Discseven View Post
Jose... Sonnen Porsche may have OEM fan and housing for $765 total. I got a few fans from them. All good.

Am using aluminum housing from Vertex. Think it was $565 when I got it. Just looked at their site... they're now getting $949. for it.

I've not heard about magnesium being repairable with any heat media. It ignites (and there's no putting it out as far as I know. Maybe Halon would kill it due to there being a lack of oxygen to burn.)

Umm yup INERT shielding gas prevents burning.. Been welding professionally for 25 years and teaching it for 17..

It has to be done correctly though.. Not weekend warrior stuff. My background is avaition and that is where its used extensively.
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Old 12-14-2017, 04:41 PM
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Just to reiterate my experience:

I got mine welded. It lasted a few months. You canít fix micro-cracks you canít see with the naked eye! Anyhow, there were no stocks of aftermarket or OEM at the time. It was just a fluke of bad luck. Thatís the reason why I got mine expertly welded.

I replaced it with a Vertex unit. YES they raised the price! I paid up the wazoooo! Oh well. At least my car is happily burning rubber up and down the block
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Old 12-14-2017, 04:51 PM
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Unfortunately its all about who welds it..
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Old 12-14-2017, 04:55 PM
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Ben / MB911, repaired the broken clutch cable boss on my early (mag) 915 transmission. He’s a pro at this stuff.
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Old 12-14-2017, 06:35 PM
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