Feb 192012

Two new fans for a Series 2 were ordered from SNG Barratt. However when they arrived they were too large to fit in the radiator cowling. The diameter of the supplied fans was approx. 1″ bigger than the originals. They had sent me fans for an XJS V12, which would explain the incorrect part number being moulded in the fan centre! They looked identical apart from the increased diameter.

So I called Barratts to explain and they said they simply trim them to the correct size. I could either send them back for Barratts to resize or do it myself. I couldn’t be bothered with the hassle of sending them back so decided to do it myself.

6mm ply was used to fabricate templates to trim off the excessIt’s a well-known phenomenon that as soon as the dreaded ‘E’ word is mentioned the cost of parts rocket skyward, to whatever the vendor and, being of a cynical nature, the vendor community think they can get away with. The fans being a case in point. At the time, an XJS fan cost £15 while the E-Type fan cost over £30 – an eye-watering mark up! So it’s worth finding out if a part was common to other models/marques.

The plan to trim off the excess from the fans was to sandwich a fan between two plywood templates. Then run a router around the template so the smooth shaft section of the router bit would butt against the template and the cutting section cut through the excess fan blade below.

Birdfeeder base was an exact diameter match which made making the templates much easierAs luck would have it, the base of a garden birdfeeder had exactly the same diameter as the original fan. So this was used to cut out the templates, using the same method above.

It also became clear as work progressed that the plan was rather over-engineered. All that would be required was a correctly shaped upper template for a section a little wider than the fan blade. A blade could be positioned under this section and trimmed with the router.

A router was then used to cut off the protruding fan bladeThe fan could then be rotated until the next blade was under the same section and process repeated until all the blades had been cut to the correct length and profile. The blade ends were then lightly sanded to remove any remaining swarf and were then ready for fitting.

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