Revisiting this whole electric fan setup. This time im going with a fan for a 2004-2007 Ford Freestar, which is damn near the perfect size for the stock radiator. Dorman #620-144.
I had to notch the shroud around the inlet/outlet a bit to get it to sit down on the end caps, and then made backets top/bottom that bolt to factory holes in the radiator. Then used some removable body push pins from some cheap assortment i bought on Amazon, to hold the fan to the brackets. Works well!
The fan controller is being powered thru a 75a continous duty relay from Obtain Surplus, triggered by a key hot source, meaning it will run as long as the key is on.
The fan controller is the FK75 from DC Control, and is a fully adjustable PWM controller with a load rating of 75a continous duty, which is more than enough for the Windstar fan setup. It has a delta temp sensor installed directly in the radiator fins to get an accurate reading of the temp of the coolant leaving the radiator. It is adjustable +/- 35º for fine tuning as well.
There is an LED installed in the dash that is feedback from the controller; it will change color based on the speed the fan is currently running. There is also an input from the A/C circuit so that it knows the A/C is on, and can adjust the fan speed accordingly.