1998 Jaguar XJR Cooling Fan Conversion

The other day we started on a 3d printing project for a customer’s 1998 Jaguar XJR Cooling Fan Conversion. One of the customer’s radiator cooling fans stopped working and the engine started to overheat. The fan assembly from Jaguar were quoted between $1100 and $1400 (for 2 fans and the shroud) We told the customer that there was a second option. The other option was to convert the fans over to brushless slimline style cooling fans.

The Process

I took about 20 measurements and traced the mounting holes. Then I scanned the tracings on my flatbed scanner. After that, I digitized the files and imported them into Fusion 360. After a few hours, the CAD files were done and it was ready to print. I stayed up until about 3am, making sure the first bracket was printing ok. It wasn’t. Some of the settings needed tweaked. I changed the settings and hit print again, praying that when I woke up the print would be good.

When I woke up 3 hours later the print was almost done and looked really nice. When that was done I removed it from the build plate. Then, I hit print again. I went into the shop to start modifying the shroud.

One of my techs ended up taking the motor apart and we extracted the OEM harness connectors. I wired and loomed that electrical connector to the fan harness. Furthermore, this made for a really nice, cohesive OEM looking connection.

Fitment

This bracket will fit the following Jaguars:

Vanden Plas – 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, & 2003
XJ6 – 1993, 1994, 1995, 1996, & 1997
XJ8 – 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, & 2003
XJR – 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, & 2003

How was it made?

The XJR Cooling Fan Conversion is printed on a highly modified AnyCubic Kobra Max 3d printer with Priline Polycarbonate CF. For example, here are the A-Z photos of how it was done, and how it all turned out.

Gallery

Front – Fans and shroud disassembled

Rear – Fans and shroud disassembled

Bolt pattern on the back of the fan shroud.

Measurements, tracings and templates we made of the shroud and fan motor mounts.

Digitizing the measurements, tracings and templates.

Drafting the digitized measurements, tracings and templates.

Bottom Angle

Top Angle

Minor modification of the slimline fans. Left side is modified.

Another shot of the minor modification of the slimline fans.. Left side is modified.

Printed bracket mocked up for some minor trimming.

Marks for trimming shroud for fitting the bracket.

How we clearanced the shroud for the bracket.

One last modification. This had a piece sticking up about 3/4″ / 20mm that has to be removed.

Test fit. Check.

Fitting the brackets, both sides

Mounting the fans.

Fans installed. Hindsight, I should have wired the plugs first.

Install – Back side

Quarter shot of the fans installed

OEM fan connectors wired and loomed

Upper fan close up of the OEM fan connector.

Lower fan close up of the OEM fan connector.

Another lower fan shot.

One last upper fan connector close up.

Front side – Complete

Ready for install

Rear – Ready for install

Side shot rear – ready for install

Front side shot – ready for install

Installed

Upper shot installed with much more room to service belts, etc.

Question / Contact Meister Werks

For more information on how to get your XJR Cooling Fan Conversion installed, please call 425-254-0627. You can also contact us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and on the westside of the Paccar / Kenworth plant.