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I elongated the holes in the lower grille block so they're both about eight inch long ovals. It was around 70F ambient on the way home last night, and the fan didn't kick on at all. Then, this morning with the ambient around 62F, coolant temps reached 196F, well below the fan activating temp of 204F. I'll keep monitoring it as the weather gets warmer. I might have to enlarge the holes just a tad more, but we'll see.
I'm wondering if version 3 of my lower grille block should have longer (horizontally) and more narrow (vertically) "slots", instead of oval holes.
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