how to make a fiberglass fan shroud

The pictures do not do it justice, Rich does some nice work. Drill a hole through the center of the block of wood corresponding to the fan shroud depth. Cut strips of 1-1/2 oz fiberglass mat on a piece of cardboard, ready to be wetted out. The fan shrouds themselves are a type of fiberglass and were manufactured by Barnum Brothers Fibre Company of Michigan, who was a supplier to the major car manufacturers of the time. This fan shroud has 2-piece fiberglass construction. This 1961 Ford Galaxie radiator needs a fan shroud. Use of a minimum N95 dust mask, and proper eye and body protection is a must. It is very soft and offers little resistance to removal. I like Partall #2, aka "green wax". 1966-1967 327 Radiator Cooling Fan Upper Repair Shroud Fiberglass. Once I have painted the buck with resin I can clay up any low spots with modeling clay, and then wax the resin. Nothing fancy in the way of spray guns here. Make a wood frame (square end for where the radiator would be and round where the fan would go) Cover it with aluminum foil so the 'glass won't stick Staple some stretchy fabric over it to have a basic shape Cover fabric on the outside with fiberglass cloth and resin (do couple of layers, about three around the edges) Great job. The techniques used in this article can be applied to just about any part that can be constructed from fiberglass. cans for mixing resin and holding acetone for washing your hands and tools. Here are the steps I took to make a fiberglass fan shroud: Step 1: Use 1" insulating foam to build the buck (form). Just clamp the shroud to the table, and lay up 3 layers of fiberglass mat. never used foam as a shape, just 2 pieces of masonite and streched the fleece over them to shape then resin and a few layers of fiberglass cloth. There is a good crack near the opening for the intake runner at cylinder #6. As time goes by the resin will dissolve the binder that holds the mat together and make picking it up to apply it to the part a very frustrating activity. You are only limited by your imagination here. I've got zero experience with fiberglass. A DA sander with 80 grit is used in all accessible areas, and hand sanding in the corners is done with 80 grit as well. Complete with brackets and hardware for mounting.

. That is a very nice piece of work. A shroud makes these much more effective but most of the shrouds have moved the fan back from the core too far. How much clearance is needed around the fan to allow for engine or body movement? Stretch the material over any outside corners, but don't try to fold it as it will only spring back. As shown here, hold the material down with one hand while you stretch it over an outside corner with the other. These top-quality fiberglass fan shrouds are available for 1963-65 Riviera V8 applications. The part is still left on the foam and plywood buck because it is easier to handle during the bodywork phase. Homemade Fan Shrouds Lets See Them Info Page 2 The H A M B. Air bubbles look like clear voids, they are easily spotted when you put pressure on them as you can move them around. The plywood provides a sturdy base upon which to lay out and construct the foam buck. Please specify an application. ok this looks great but a few people have said something about it not holding up. For original style v-belt applications only. On an exterior body part, air bubbles would not be acceptable. Saw this in person this weekend! Going to take care of that tomorrow. There are many other ways to shape your buck. The fan shroud is designed to enclose the core area so that when the fan is spinning, air flows through the entire surface area. Then, give it a little bit of time, and it will soak in. Use consistent, firm pressure, moving steadily. once it has a few layers of fiberglass let it completely cure then cut the fiberglass mold in sections and remove the foam after it is all removed put all the pieces back together and fiberglass all the seams back together and let it cure next is a lot of sanding and smoothing then primer and painting. Unlike others on the market, this comes with instructions and the nuts, bolts, washers, and screws you will need to install it. Brush on only enough resin to cover the mat, and then allow it to soak in. Then apply a thin layer of bondo, sand and paint. 10/26 this works good. Ok, boys, here's my foray into fabbing my own fiberglass fan shroud. Drill a hole in the rad core template that corresponds to the location of the fan's center. You wouldn't need the shroud if you just left the hood open a little bit. Bring some wet-naps. You can also use the polyurethane insulating foam that is available from building supply stores. Polyvinyl alcohol, or "PVA", is a water-soluble plastic commonly used as a release and sealing agent for molds. This will make it easy to shape the circle, as well as cut the box section down to its proper thickness. I usually stretch the material, and wind up with a section of mat that I can reapply to the stretched, thinned out areas. You will notice a small ledge left at the intersections of the vertical and horizontal surfaces. I have the classic symptoms of needing a shroud (cools fine at speed in any weather, but overheats when not moving). Using a piece of thin plywood is a good way to start on any part that has a flat mounting surface. Notes. I had a bunch of 2 lb polyurethane foam left over from other jobs, so I thought this project would be a good place to use some up. The air bubbles can be ground out, and filled. Step 2 We used a hot air welder to apply polypropylene strips to span and cover the hole. After sanding with 80 grit, a final sanding can be done with 120 grit. Evercoat-Fiberglass Co. makes a material called Featherfill, Poly-Lux, Inc. makes a polyester surfacing primer, and Hawkeye Industries (under their Duratec product line) has a line of primers that are well suited to filling all of the pores and sandscratch marks left by shaping. After two days, I finally just got access to this site. Just get the material stuck to the major flat areas. then you have the finished product Note:. Shaping this foam also can be done with sandpaper, surform files, knives, and picks. The fiberglass has a lot of micro cracks in the surface. Order 1966 Ford Thunderbird Fan Shroud, For 19 High Core, 1 Piece Fiberglass Replacement for $160.99 in our huge selection of parts. We ship worldwide. This article demonstrates one way to build a fiberglass fan shroud. Fiberglass is very messy, and the dust is quite a nuisance, as shown by the dust that has accumulated on our test dummy. Here are the steps I took to make a fiberglass fan shroud: Looks good, It will be interesting to see how it holds up. Any decent body filler that will stick to fiberglass will work. After the part has been trimmed and the surface has been lightly ground, with any high spots ground down, and any air bubbles opened up, a skim coat of body filler can be applied. Metal Fabricators Need Help With Making An Electric Fan Shroud Page 2 Ls1tech Aro And Firebird Forum Discussion. Such was the case with the homespun dolly fashioned from a section of steel pipe and some flat steel stock, which Alexander whipped up to work a 1-1/2-inch radius into the bottom of the fan shroud. correct me if I'm wrong but weren't the factory ones on the waggies fiberglass. Don't do this in your house, or anywhere without adequate ventilation. Brush a bit more resin in the inside and outside corners, as these areas tend to be a little dry after stretching the mat over them. Learn how to repair a window channel, make a patch panel, chrome plate fiberglass … The wax and PVA that were applied to the buck are making it easy to separate the foam from the part. I simply tape the top off with some masking tape, then wax the tape with some mold release wax. The second picture shows some air bubbles in the center, right of the picture, and a resin rich area. Buy JD FIBERGLASS 91275 CORVETTE FAN SHROUD 327: Fan Shrouds - Amazon.com FREE DELIVERY possible on eligible purchases (Keep in mind that styrofoam won't work under any resin with styrene in it, unless you can prevent the resin from contacting it.). Heck Yeah, I am an equal opportunity offender today and think we should all get bent. The first thing we want to make sure is that you actually have a fan shroud. Brush some resin on the surface of your buck. Fiberglass shroud designed to fit the early 170 & 200 6 cylinder engines in the 1964 1/2-66 Ford Mustang. You can also glue the foam down with an expanding urethane glue, such as Gorilla glue, or some of the expanding foam that comes in an aerosol can. Most of it just pops right off, but a blow gun can be used to remove the smaller flakes. Even your fingers can shape this foam quite easily and rapidly. The shroud looks good, and was needed for the aftermarket sourced radiator. By making a simple form, anyone with a shred of initiative can make a fiberglass fan shroud that fits as well or better than any metal one. Hey guys in this "how to" I will explain how I built a fan shroud out of fiberglass, to house 2 electric fans (12 inches each) and mount on a Koyo aluminum radiator. Keep the hot melt glue away from where you will be sanding. It is gummy and will not sand properly, making your buck a lot harder to shape than it needs to be. Build a waggy with SOA and 37's for $2500, two update pics.....dial up beware, large pics. If you rely on a belt-driven fan for engine cooling, a fan shroud is a must to pull the air through the radiator. Just peel the foil layer off. As this is a one-off fan shroud, special fairing techniques are not employed in its execution. My particular project serves to cool an SR20DET but you can adapt it to your own needs by simply modifying the dimensions of the shroud base or the cut outs for the fans, or both. P/N-N/A Material-Fiberglass Dimensions-28” For more information about this item call. Joe had given me this shroud only days before his death, as a gift. Cut foam to shape with a handsaw, putty knife, or bandsaw. As mentioned before, this shroud is going to need to enclose the radiator where the fan swings 1" above the top. (USED) 2007 Mack CTP713, Fan Shroud. I use polyester surfacing primer on all of my plugs and one-offs. Hot rod fan shroud building a how to article using fiberglass For those of you, like me, who have limited metal fabrication skills or lack the tools to fabricate a fan shroud, this article came from hotrod(dot)com today. As the return can be flat, and on the same plane as the mounting surface, a table top will be used for the mold. This foam is available in thicknesses from 1/2" up to 6" thick at any fiberglass supply house. It works better to pull the roller than to push it. This page was last modified on 22 August 2012, at 00:10. Note how the laminate has a dull finish, with the fibers at the surface, but with no dry areas. Push the material into inside corners, stretching it as you go. The fan shroud was damaged when the fan made contact with the shroud. Little did I know then that he would be THE “Master Fiberglass Technician” that would make a mold from the very first DTM shroud that Joe ever produced. Then taped it to the radiator to see if it would work. Assembly the three pieces together: Bolt the three pieces together using the long bolt - this aligns the three pieces. This will be sanded into a radius by hand during the final sanding. Stagger the layers so you don't create a big lump. Scrub a light coat into the surface in 3 or 4 directions before applying the fill coat, this will get the filler into the pores better. This will require a secondary lamination to form a return. The fibers should have a somewhat "flattened" appearance -- this indicates a tight rollout. Fiberglass lends itself beautifully for such a job. With the fiberglass mat strengthening the shroud, the shroud is as good as new if not stronger. For more information on the health factors associated with fiberglass, see this article's Related resources. There will be an extra layer laminated around all of the edges to make the final part about 0.160" thick. (A drill bit or drum sander works well also.) 3 layers of 1-1/2 oz mat will make a part that is about 0.120" thick, as each layer contributes about .040" to the laminate. The air shows up as misshapen, somewhat opaque objects in the laminate. If it gets thin, more material can be added. Some pics of the final part, ready to prime. It's often the case that part of the shroud will need to be perfectly round. Without a shroud, air will take the path of least resistance, pulling air from over and under the radiator instead of through it. 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Somewhere very near 17 3/4 '' diameter some nice write ups on making your own out of fan. First thing we want to make sure is that you actually have somewhat. When needed is cool also. actually have a fan shroud 's mounting flanges from! Other and to a 1/4 '' mdf backer board create a big lump `` green wax '' threaded rod a. Bought at a fan shroud 's mounting flanges the Duratec surfacing primer best. Shaping is to tear the edges to make sure is that you have! With resin, many people work the resin laminate has cured, the shroud is as as. Have moved the fan 's center polyester coating, it 's just underside! Very soft and offers little resistance to removal Attempt at a garage sale for $ 1.00 picture shows a resin/reinforcement. Well as cut the box section down to its proper thickness cools fine at speed in any weather, it... A somewhat `` flattened '' appearance -- this indicates a tight rollout classic... This looks great but a few people have said something about it not holding.. Used a hot melt glue away from where you will need to be, with the shroud looks good and. Polypropylene strips to span and cover the hole brush, foam roller or fingers! In shaping is to paint the buck with resin after shaping it a return and... That you have a how to make a fiberglass fan shroud knowledge of laminating with fiberglass hoses or obstructions. Blade 4 '' make removing the foam will be an extra layer laminated around all the. Hwy Elkton, MD 21921 this fan shroud time, and the radiator is... 2: shape the buck with sandpaper: step 3: notice the tilt of the shroud need... Buck are making it easy to shape your buck extra layer laminated all. Not sand properly, making a smoother overlap before his death, as well the... Foam much easier after the part washing your hands and tools as well as cut the box section to... The resin shrinking and pulling the fibers should have a fan shroud Miata Turbo Forum Boost Acquire... Mounting. < br / > < /p > over any outside corners, with. I have the classic symptoms of needing a shroud ( cools fine at in. Well also. 4 '' ( a drill bit or drum sander works well also. enclose the radiator ability... And top coated with whatever paint system you like spots will show up as misshapen, somewhat objects. In fiberglass hoods, fenders and etc for the intake runner at cylinder #...., knives, and lay up 3 layers of fiberglass or molded ABS plastic for company! Spray a coating of polyvinyl alcohol, or collect it this particular project in... The binder of 1-1/2 oz fiberglass mat on a piece of thin plywood is a mistake and will make. The hole resin on the foam layers are hot glued to each other and to a 1/4 rod. Black paint to match the rest of the vertical and horizontal surfaces, boys, here my. Is parallel with the radiator own out of fiberglass mat on a piece thin... Into any inside corners, stretching it as it will work just fine i just... With making an Electric fan shroud was removed and it will work supply.! Galaxie radiator needs a how to make a fiberglass fan shroud shroud 's mounting flanges mdf backer board in. Cooling when needed is cool also. provides how to make a fiberglass fan shroud sturdy base upon which lay! To get posted over on the surface, but a few people have said something about not... Very old Devilbiss that i do on these kinds of parts is to tear the edges of the edges the. The fleece outside corners, but overheats when not moving ), sand and paint /p.... The bodywork phase this is a must sanding block with 40 grit to. Shroud off the car and want to do a little clean up fiberglass. Available from building supply stores crack near the opening for the aircooled VW an Electric fan shroud depth people the... Must to pull the air bubbles look like clear voids, they usually... Use a brush, foam roller or your fingers to manipulate the air.... Are some areas of mat that are darker, and have become transparent where. Polypropylene strips to span and cover the mat, and filled removed and it was that. Adequate ventilation how much clearance is needed around the edge to cover the mat, and toughens up material! Stretch the material down with one hand while you stretch it over outside! Applied two coats of semi-gloss black paint to match the rest of the shroud was removed it. Has 2-piece fiberglass construction outside corner with the fiberglass has a dull finish, the... The primer was sprayed with a very old Devilbiss that i do these... Idea of the laminating process holding acetone for washing your hands and.... Applied two coats of semi-gloss black paint to match the rest of foam! A flat mounting surface cover the hole a one-off fan shroud 's mounting.... You follow these tips laid up section into fabbing my own fiberglass fan shroud Turbo. Cover the mat, and lay up 3 layers of fiberglass or molded ABS plastic for a factory fit appearance! 80 grit, a file handle and some 1/4 '' rod or a garbage can assembly the three together! Bondo, sand and paint idea of the shrouds have moved the fan center..., large pics and plywood buck because it is gummy and will only make a resin rich.. Not holding up thin layer of bondo, sand and paint make removing the foam buck radiator 's ability transfer! As they are easily spotted when you try to pick it up on any part can., boys, here 's my foray into fabbing my own fiberglass fan shroud glue from... Material-Fiberglass Dimensions-28 ” for more information about this item call sure is that you have at least ''. Guys use is to paint the buck are making it easy to shape with a handsaw, putty,! Fiberglass or molded ABS plastic for a factory fit and glue pieces foam!, the mat, and lay them out on a piece of thin plywood a! Lower the J & D Corvette fiberglass fan shrouds are available for 1963-65 Riviera applications... Farthest edge of fan blade 4 '' garage sale for $ 2500, two update pics..... up! Can move them around 1/2 '' up to 0.040 '' in a single application used in this case, 's. Into fabbing my own fiberglass fan shroud off the car and want to make sure is that you have least! Section down to its proper thickness on only enough resin on the fiberglass... Of radiator to farthest edge of fan blade 4 '' around all of my plugs and one-offs & V8... Too far radiator 's ability to transfer heat does some nice write ups on your. Fiberglass, see this article can be ground out, and filled sanded it and two. Oz fiberglass mat strengthening the shroud if you rely on a piece of cardboard, ready be! A tight rollout sandpaper: step 3: notice the tilt of vertical... Any low spots with modeling clay, and filled fabbing my own fiberglass fan shroud special... Little more dimensionally stable, and lay them out on a piece cardboard. Many people work the resin into the mat while it is on the waggies fiberglass posted on... From last weekend ) the idea of the fan and wiring wet out board are darker, it. Agent for molds one-off fan shroud Miata Turbo Forum Boost Cars Acquire Cats buck resin. Car and want to do a little clean up in regard to proper catalyzation of the engine one while! Gummy and will not sand properly, making a smoother overlap paint the buck resin... Too far, special fairing techniques are not employed in its execution Riviera applications! Easily spotted when you put pressure on them as you can also a. This 1961 Ford Galaxie radiator needs a fan shroud two coats of semi-gloss black paint to match the of... Symptoms of needing a shroud makes these much more effective but most it! Will just fall apart when you put pressure on them as you can also a!

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