I had to do so much of this same research for the Critical Information Circuit that its almost all done for me. This is what the lug that I designed looks like:
http://devestechnet.com/Images/Projects/WarningSystem/WarningSystem0041lg.jpghttp://devestechnet.com/Images/Projects/WarningSystem/ThermistorLugHousing.jpgThe Thermistors are held in by bending the tabs over. This puts them up against the lug metal, then high temp silicon covers everything. This has been tested over and over and the results are every bit as good as an immersed sensor.
What does the lug look like that connects to yours?
The reason I asked about one or two wires is because I figured out how to use one wire to the thermistor with the other one soldered to the lug itself. Less wires to break is always a good thing. Then since there will be two thermistors, I will use shrink tubing for the first foot or so from the lug, then small pieces of shrink tubing every 6 inches to the box.
The box would have the circuit kill switch mounted to it since it would be pretty rare you would ever use it, if at all. The override switch can go anywhere you choose. The box would need to be mounted so you can get a screwdriver inside the holes for the small circuit board potentiometers to adjust the temperature of each fan ON condition. I will preset them so FAN1 comes on at 185 and FAN2 comes on at 190 or whatever you guys think makes sense. For one fan, just ignore the FAN2 part.
I hear that Mike. Keeping things stock looking is the hard part with some of this stuff, but its all possible with a little creativity.
