I have been making progress. One of the objectives of this build is too ditch the electric fan. The automatic transmission needs to stay cool, probably more than the engine. With a complex cooling system - engine, air conditioning and transmission, the mechanical fan seems the best option. The original Duratec engine was fro a Ranger and used a mechanical fan. All I have to do is replace the front casting, a timing chain cover. No problem.
Ooops, big problem. The timing chain cover will NOT come off. All the bolts are out, but cover is not loose. There has to be a hidden bolt. Sure enough, and it is hidden behind the fan pulley. No way to remove the bolt unless I remove the pulley. This is a pulley I made 10 years ago and installed onto stock fan spindle. I thought my mount was rather dodgy, so I used non-removeable lock tite during installation. I can state that when they say non-removeable, you'd better pay attention. I had to cut the old pulley off, using an angle grinder and cutting disc.
Once the pulley was off, it took about 15 seconds to remove the chain cover. Fortunately, I still have some of the aluminum slug the pulley was made of, so I was able to make another. Here the inside diameter is being threaded. 1 13/16" - 20. A nice thing about a machine shop, you can develop your own thread system.
After threads, the back of the pulley had to be hollowed out.
This is the spindle the pulley mounts on.
Here is the pulley, ready to mount. The studs are to mount the fan. Note the hole to access the cover bolt. I do learn, sometimes.
Here is the pulley mounted on the spindle.
Fan, with viscous drive, mounted on the pulley.
Bill