I broke down and did it. I had a piece of sheet aluminum lying around and set my mind to do a homemade electric fan kit. I wasn't impressed with what available for the crd so I tried to see if I could do better. I think I did, but my approach was to do it as cheap as I could.
I bought 2 10inch fans from ebay for 42.00 dollars that had a total of 3500 cfm, and a basic hayden tstat electric fan kit 29 dollars. I used a brake from harborfreight (30 inch one). I used rubber grommet that I got from flex a lite so I wouldn't have metal to metal. I used a jig saw to cut my circles.
The other fan kits offered had a basic 18x18 shroud which left about a inch all around on the sides. I wanted more coverage so the fan would pull across as much air through the radiator as possible.....like the stock one did soooooo....there you have it. I ended up with a 20 x 20.25 x 1.....not really skill just lucky mistake. It fit perfectly, well maybe a little too good. I started by cutting a sheet down to 22 x 22 and ended up with what you saw previously. If I could go back I would want a 19.75 x 20.25 x 1-1.5. Honestly, unless you are good you wont get that precise. you just have to try and get lucky or get someone to build it for you.
Using a brake was challenging...especially after you get two of the side that are easy. then you will be challenged on getting a piece of metal that fits between the two 20 inch sides. My suggestion would be to get a 45 degree angle iron and cut to size. I used a smaller brake iron from a different set (18 inch one) or you just try to find a premade one and even make the one they sell on ebay for less. You can try sheet metal but you will have to paint or bumper coat.
Electric fans were difficult to find 16inch fans range from 2000cfm to 3600cfm prices range wide too...60 bucks to 150 dollars. so I searched and searched and came up with the two ten inch fans that totaled 3500cfm (their specs) beside, a 16 inch 3600 cfm isn't doing what it is supposed to do if it doesn't cover 100 percent of available radiator surface area.
Mounting to stock locations was easy. two bolts grinded down so they were flat instead of round for the bottom and I used banjo bolts for the top and just drilled holes in the side of frame and wala. I'm sure there may be a better way but sometime easy is the best until someone can come up with better. I used stock bolts and stock mount tabs.
I will add pictures but I just wanted to give you the gist just incase you want to build it youself. I cant say it will be cheaper but I believe it will be better that what you can buy. I spent 70 dollars total but I pulled favors. but I still think you can build for under 300 even if you had to buy everything...and the good news is that you will have tools left over to use for something else and a fan that will pull better that anything you can currently buy today.

Nice project. Consider posting some pics?

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05CRD: GDE Hot ECU & TCM tunes, Provent, Cat filter, Facet lift pump, TransGo kit, Florida TC, Samcos, stainless brake lines, HDS thermostat, Renegade light bar,
Bilstein adjustables, Al's Gen 4.5 Arms, 235/85-16 Duratracs, DTT rear, Elocker front, EVIC+TPMS, Turbo timer, McNally pillar gauges, Weeks Stage II kit.

Not sure I know how...I may have to email them to you.

Post them to photobucket or other similar site then down load to here

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MUDD'S MOTORSPORT'S We do IFS lift installs ,
03 OVERLAND EDITION /Kilby-Skidrow-Mopar-4XGuard skids/ 2.5 inch TOTAL CONTROL JBA coilovers -JBA Arms/MOABS-31 FALKEN WILDPEAK AT3W / 4.10's etc, 04 Kilimanjaro Edition loaded, plus 05 KJ limited

http://s44.photobucket.com/user/roadrun ... 7.jpg.html




Hopefully this is it.

Put [img] on the left of the pic link,

then put [/img] on the right side, taking off .html so the url ends in .jpg

Or, actually, just click on the little box to the right of your photo that says IMG on it and copy.

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2005 Liberty Renegade, Bright Silver Metallic

Looks awesome! Great job

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2003 Sport
3.7 45rfe
LOKKA Rear locker
OME 927 NS131's
JBA top plates
JBA A-Arms
3 ring clevis
Terraflex bump stops
OME 948 extra iso N132L's
Hockey pucks
Optima Red Top
Cobra 19 4' Firefly on Tram Triple Mag Mount
MOABS W/ 245/75/16 E Duratracs
ASFIR ARMOR
Rock Lizard Super Skink's
Other Stuff................


Size 13 Carbon Foot Print