My overheating problem is officially solved with the Taurus cooling fan. The car has been off the road for the entire month of July as I have had Armando modifying the
oil pan to clear the rear main bolts. After installing the fan and getting it all back together I finally hit the road this afternoon. I had wired the low speed to the 185* inline thermo switch and the high speed is wired to a dash toggle. Outdoor temps today were in the low 90's and humidity was 60%, It was very muggy and hot and I started by letting it idle in the driveway for 20-30 minutes. It never got above 190*F with the fan on low. I then went out and pushed the car pretty hard. I never had to turn the high speed on as the car stayed right a 185-190*F, even stopped in traffic. I suspect that if it were 95-100* outside I might need the high speed, but even that is a maybe.
After all is said and done, I don't think its the fan itself as much as the proper shroud. The Taurus shroud covers nearly all of the 27"x19" PRC radiator surface used by Hurricane, and that's far more coverage than I was getting with the 16" round Zirgo fan. My only gripe about the Taurus fan is the shroud edges are molded to fit some variations on the edge of the Taurus radiator and so its doesn't look extremely original. But I think I can solve most of that with some trimming and sanding/filing.
Another factor in this was the timing, which was probably advanced a bit too much at 20* (the folks at Demon seem to think more advance solves all problems I guess.) Patrick helped me work through that and provided offline education and moral support. I feel much more competent in FE tuning and timing thanks to him.
Also thanks to David Gagnard and all of you who posted your advice and comments and sent emails and PMs. Maybe this thread will be helpful to others in the future.
Jim
P.S. All the above was with the 180*F NAPA standard Ford OEM t-stat drilled with 4 holes, and nothing but distilled water.