Problem is that my application is custom (summit alum radiator) AND my fan overhangs the radiator in 3 places, so a prefab or kit alum or stainless shroud just won't do it. The shroud has been scraped and the color is fading. Fiberglass is very messy, and the dust is quite a nuisance, as shown by the dust that has accumulated on our test dummy. As this is a one-off fan shroud, special fairing techniques are not employed in its execution. Also, if I was going to make several of these parts, I could sand and polish the surface, wax it, and use it to create a mold with which I could duplicate it many times over... Just click the "edit" tab at the top of this page, or click one of the [edit] links to the right of an article section. Brush some resin on the surface of your buck. Order 1966 Ford Thunderbird Fan Shroud, For 19 High Core, 1 Piece Fiberglass Replacement for $160.99 in our huge selection of parts. Stagger the layers so you don't create a big lump. Cut foam to shape with a handsaw, putty knife, or bandsaw. Don't try to push it into any inside corners or stretch it over any outside corners just yet. Then, fit and glue pieces of foam larger than your layout on the board. For more information on the health factors associated with fiberglass, see this article's Related resources. (USED) 2007 Mack CTP713, Fan Shroud. Nice write-up,'where do you get the fleece? There is no more resin on those strips than is on the others, they were wetted out earlier and have soaked up the resin. I'm gonna lick everything you butt doesn't touch!!!! Just get the material stuck to the major flat areas. In the first picture, the white streaks and crosses are the result of a slightly stressed part; this one was from the laminate being in the sun and curing too fast in that spot. We ship worldwide. Joe had given me this shroud only days before his death, as a gift. 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. There are many other ways to shape your buck. Fan manufacturers have continued to reduce the thickness of the fans and now there is a shroud from Cool Craft that when combined with the fan only measures 2-5/8-inches thick. One step that I do on these kinds of parts is to paint the buck with resin after shaping it. center of fan is 8 14" down from inside seam. The glass transition temp of Polyester resin is on the order of 50 degees C or ~122 Degrees F and tends to degrade with moisture. The air shows up as misshapen, somewhat opaque objects in the laminate. Polyvinyl alcohol, or "PVA", is a water-soluble plastic commonly used as a release and sealing agent for molds. The primer was sprayed with a very old Devilbiss that I bought at a garage sale for $1.00. (Keep in mind that styrofoam won't work under any resin with styrene in it, unless you can prevent the resin from contacting it.). I've got zero experience with fiberglass. Drill a hole through the center of the block of wood corresponding to the fan shroud depth. Nothing fancy in the way of spray guns here. You do need to be somewhat swift with this part of the laminating process. I use polyester surfacing primer on all of my plugs and one-offs. Each shroud is manufactured to OEM specifications and includes correct mounting tabs as well as the upper radiator hose support mount where applicable. 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. Looks good man...Del. I am not up on my composite materials, so I am not sure if there is any good room temp cure resins for high temp use. Once I have painted the buck with resin I can clay up any low spots with modeling clay, and then wax the resin. Does A Fan Shroud Make Difference. It works extremely well for rolling out air bubbles in fiberglass. These top-quality fiberglass fan shrouds are available for 1963-65 Riviera V8 applications. This greatly increases the radiator's ability to transfer heat. 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. As the return can be flat, and on the same plane as the mounting surface, a table top will be used for the mold. There is a good crack near the opening for the intake runner at cylinder #6. This will be sanded into a radius by hand during the final sanding. 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. Notice in the picture how there are some areas of mat that are darker, and have become transparent. As mentioned before, this shroud is going to need to enclose the radiator where the fan swings 1" above the top. It is the resin shrinking and pulling the fibers apart that causes that appearance. After two days, I finally just got access to this site. It is very soft and offers little resistance to removal. Don't do this in your house, or anywhere without adequate ventilation. With the fiberglass mat strengthening the shroud, the shroud is as good as new if not stronger. Note how the laminate has a dull finish, with the fibers at the surface, but with no dry areas. (joke from last weekend) The idea of the pusher fan as additional cooling when needed is cool also. On an exterior body part, air bubbles would not be acceptable. Shop restoration car parts and accessories at Ecklers. The first thing we want to make sure is that you actually have a fan shroud. In this case, it's just the underside of a fan shroud, so it will work just fine. Fiberglass lends itself beautifully for such a job. The part is still left on the foam and plywood buck because it is easier to handle during the bodywork phase. so, I figured it is time to learn how to fiberglass I took a bunch of measurements and ended up at 24 1/4" x 17 3/4" radiator inside seam. Push the material into inside corners, stretching it as you go. Then, give it a little bit of time, and it will soak in. 1966 Ford Thunderbird Fan Shroud, For 19 High Core, 1 Piece Fiberglass Replacement Combined Cancer/Birth Defect WARNING This product can expose you to chemicals including Phthalates which is known to the State of California to cause cancer on birth defects or other reproductive harm. Are there any noteworthy angles or off-center components? Brush on only enough resin to cover the mat, and then allow it to soak in. The shroud was removed and it was determined that the shroud was made out of polypropylene. Cut the shroud away from the form today. same technique as speaker enclosures. Fiberglass shroud designed to fit the early 170 & 200 6 cylinder engines in the 1964 1/2-66 Ford Mustang. I simply tape the top off with some masking tape, then wax the tape with some mold release wax. The plywood provides a sturdy base upon which to lay out and construct the foam buck. 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. 10/26 This page has been accessed 84,661 times. "Dry" spots will show up as white strands of fiberglass that spring up out of the resin. Ok, boys, here's my foray into fabbing my own fiberglass fan shroud. The fan shroud was damaged when the fan made contact with the shroud. Here are the steps I took to make a fiberglass fan shroud: Looks good, It will be interesting to see how it holds up. This is a mistake and will only make a resin rich, inconsistent part. After sanding with 80 grit, a final sanding can be done with 120 grit. Enjoy the videos and music you love, upload original content, and share it all with friends, family, and the world on YouTube. Unlike others on the market, this comes with instructions and the nuts, bolts, washers, and screws you will need to install it. You are only limited by your imagination here. Brush some resin on the surface of your buck. Pick up the material from the wet out board and apply it to the part. Assembly the three pieces together: Bolt the three pieces together using the long bolt - this aligns the three pieces. Squeegees don't work well on fiberglass mat. It is parallel with the radiator, and there are no hoses or other obstructions to deal with on this particular project. Before installation, we sanded it and applied two coats of semi-gloss black paint to match the rest of the engine bay. 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. This will require a secondary lamination to form a return. David worked for a company that was the leader in fiberglass hoods, fenders and etc for the aircooled VW. Even your fingers can shape this foam quite easily and rapidly. 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. Use of a minimum N95 dust mask, and proper eye and body protection is a must. The third picture shows another shot of a resin-rich area, and the fourth picture shows a proper resin/reinforcement ratio. Then apply a thin layer of bondo, sand and paint. 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) That would be another good post- the fan and wiring. You wouldn't need the shroud if you just left the hood open a little bit. When we are done with this article, it will have a fan shroud that looks like this: Start by measuring all of the dimensions, taking care to consider all of the following: For example, this fan is off-center towards the passenger side by about 1/2", sets back about 1-3/8", and it swings about 1" above the top of the radiator. Great job. Now that this part is primed with the polyester coating, it can be sanded and top coated with whatever paint system you like. The air bubbles can be ground out, and filled. Heck Yeah, I am an equal opportunity offender today and think we should all get bent. correct me if I'm wrong but weren't the factory ones on the waggies fiberglass. How will the shroud attach to the radiator? 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. If it gets thin, more material can be added. The dust will migrate everywhere if you don't exhaust it, or collect it. 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. I have the classic symptoms of needing a shroud (cools fine at speed in any weather, but overheats when not moving). To laminate the part, you will need the following: This article assumes that you have a basic knowledge of laminating with fiberglass. This 1961 Ford Galaxie radiator needs a fan shroud. Fan is somewhere very near 17 3/4" diameter. This foam is available in thicknesses from 1/2" up to 6" thick at any fiberglass supply house. It is gummy and will not sand properly, making your buck a lot harder to shape than it needs to be. A trick that professional 'glass guys use is to tear the edges of the mat. The plywood that is still sticking out from under the foam will be used to form the flat mounting flanges. Reproduction fan shrouds are professionally manufactured to OEM specifications using either fiberglass or molded ABS plastic for a factory fit and appearance. Using a piece of thin plywood is a good way to start on any part that has a flat mounting surface. How much clearance is needed around the fan to allow for engine or body movement? this works good. Add this to the 'future project' list. Fiberglass Fan Shroud 1964-66 Mustang 170 200 engine | eBay Shrouds are sold per each. Follow all instructions provided with your materials in regard to proper catalyzation of the resin and storage and handling of your tools and materials. Drill a hole in the rad core template that corresponds to the location of the fan's center. Complete with brackets and hardware for mounting.
. The techniques used in this article can be applied to just about any part that can be constructed from fiberglass. Homemade Fan Shrouds Lets See Them Info Page 2 The H A M B. cans for mixing resin and holding acetone for washing your hands and tools. The shroud looks good, and was needed for the aftermarket sourced radiator. Then taped it to the radiator to see if it would work. from backside face of radiator to farthest edge of fan blade 4". At the time of this writing, Z&M Jeeps offers a repro fiberglass shroud for $110 and BJ's offers a nice welded aluminum shroud for $175. MADE IN THE USA Displayed are all the parts that make up the Bernie Bergmann High Flow Fan Kit Fiberglass Shroud, Paint Grade 110 Amp Alternator, Internal Regulator wear protective equipment when handling fiberglass or cutting fiberglass I usually stretch the material, and wind up with a section of mat that I can reapply to the stretched, thinned out areas. Once the laminate has cured, the part can be removed from the table. My First Attempt At A Fan Shroud Miata Turbo Forum Boost Cars Acquire Cats. Mdill, what would be a better material to use for making a shroud that is going to be subjected to such intense temp swings? Post the year and model for everyone. It will also serve as the form for the finished fan shroud's mounting flanges. by: Cobalt327, Jon, Powerrodsmike, Willys36(Click here to edit this page anonymously, or register a username to be credited for your work.). A wedge of foam was glued in to account for the tilt of the engine. Step 2: Shape the buck with sandpaper: Step 3: Notice the tilt of the foam. Stuff like this needs to get posted over on the 'network' so it's not lost. Granted although it is probably not as strong as a shroud made completely out of fiberglass, ultimately, the only “flying debris” issue of concern is not self-destruction but rather the small amount of Bondo used to make the patch lines look good. That is a very nice piece of work. Here are the steps I took to make a fiberglass fan shroud: Step 1: Use 1" insulating foam to build the buck (form). Though fiberglass dust and fiberglass strands are generally not considered to be carcinogenic (except in cases of uncommonly high exposure), they are widely recognized as skin, eye, and respiratory irritants. Using PVA will make removing the foam much easier after the part is laid up. It's correct for 352 & 390 V8 With Heavy Duty Cooling Or Factory A/C. It makes it a little more dimensionally stable, and toughens up the surface for the next steps. the last two I bought both still had them, they looked factory and I know for a fact they were fiberglass and these rigs were 20-30 years old and the shrouds were still holding up. Keep the hot melt glue away from where you will be sanding. I made a small miscalculation in the fan tube size and had to add some foam around the edge. As shown here, hold the material down with one hand while you stretch it over an outside corner with the other. 1966-1967 327 Radiator Cooling Fan Upper Repair Shroud Fiberglass. Exterior fabrication can be a daunting task, but it doesn't have to be if you follow these tips. Step 2 We used a hot air welder to apply polypropylene strips to span and cover the hole. Just clamp the shroud to the table, and lay up 3 layers of fiberglass mat. Notes. Saw this in person this weekend! The different glues can make sanding over seam lines difficult, as they are usually a different density and hardness than the surrounding foam. Bought another one today...dial up beware!! I have the fan shroud off the car and want to do a little clean up. Some pics of the final part, ready to prime. If the binder has dissolved, the mat will just fall apart when you try to pick it up. Just peel the foil layer off. If you pull some material off the edge, you can put it back over the outside of the corner, as it has probably gotten a bit thin there anyway. I had seen some nice write ups on making your own out of fiberglass or a garbage can. 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. Going to take care of that tomorrow. You can also use a brush, foam roller or your fingers to manipulate the air out. Cut strips of 1-1/2 oz fiberglass mat on a piece of cardboard, ready to be wetted out. 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. A shroud makes these much more effective but most of the shrouds have moved the fan back from the core too far. This tapers the thickness down at the edge, making a smoother overlap. Move slowly, applying enough pressure to roll the air out, but not so much pressure that you move the mat around or push all of the resin out. (A drill bit or drum sander works well also.) This fan shroud has 2-piece fiberglass construction. I use a diamond saw on a die grinder to trim parts, but you can use a grinder with a 24 grit disc or sawzall just as easily. The fan shroud is designed to enclose the core area so that when the fan is spinning, air flows through the entire surface area. Work quickly but carefully, as the resin will gradually dissolve the binder. ive made them for my hotrods, where there is no factory shroud. The second picture shows some air bubbles in the center, right of the picture, and a resin rich area. 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. Now the foam buck can be chiseled out. Cut your material so that you have at least 1" of overlap onto the previously laid up section. A hot melt glue gun makes gluing this foam fast and easy. Metal Fabricators Need Help With Making An Electric Fan Shroud Page 2 Ls1tech Aro And Firebird Forum Discussion. For original style v-belt applications only. The final step in shaping is to radius the square outside corners with sandpaper. Air bubbles look like clear voids, they are easily spotted when you put pressure on them as you can move them around. You only brush enough resin on to cover the mat with resin. If you rely on a belt-driven fan for engine cooling, a fan shroud is a must to pull the air through the radiator. Done correctly and applied while the previous lay up is still workable, you won't be able to tell that the part was made from separate pieces of mat. This article demonstrates one way to build a fiberglass fan shroud. P/N-N/A Material-Fiberglass Dimensions-28” For more information about this item call. Use consistent, firm pressure, moving steadily. Any decent body filler that will stick to fiberglass will work. The fiberglass has a lot of micro cracks in the surface. This page was last modified on 22 August 2012, at 00:10. There will be an extra layer laminated around all of the edges to make the final part about 0.160" thick. 929 W Pulaski Hwy Elkton, MD 21921 I made a roller out of some threaded rod, a file handle and some 1/4" rod. Learn how to repair a window channel, make a patch panel, chrome plate 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. It's often the case that part of the shroud will need to be perfectly round. Use a sanding block with 40 grit sandpaper to taper the edges of the plenum box down. It also can illustrate how easy it is to use this foam -- it cuts so easily and shapes so well that piecing it up doesn't add all that much time to the project. The pictures do not do it justice, Rich does some nice work. 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. I've been frustrated by the difficulty of finding a decent replacement fan shroud for my J10 with the AMC 360. What's the distance between the fan and the radiator? I like Partall #2, aka "green wax". Thanks for all the comments. You can also use the polyurethane insulating foam that is available from building supply stores. Shaping this foam also can be done with sandpaper, surform files, knives, and picks. This will make it easy to shape the circle, as well as cut the box section down to its proper thickness. The foam layers are hot glued to each other and to a 1/4" mdf backer board. And horizontal surfaces layer of bondo, sand and paint inconsistent part air welder to how to make a fiberglass fan shroud... 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Resin rich, inconsistent part proper resin/reinforcement ratio, and there are no hoses or obstructions!: //www.crankshaftcoalition.com/wiki/index.php? title=Make_a_fiberglass_fan_shroud & oldid=24818 for the aircooled VW a factory fit and glue pieces of foam was in...