Here are the steps I took to make a fiberglass fan shroud: Looks good, It will be interesting to see how it holds up. ive made them for my hotrods, where there is no factory shroud. The air bubbles can be ground out, and filled. Unlike others on the market, this comes with instructions and the nuts, bolts, washers, and screws you will need to install it. 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. It is gummy and will not sand properly, making your buck a lot harder to shape than it needs to be. Order 1966 Ford Thunderbird Fan Shroud, For 19 High Core, 1 Piece Fiberglass Replacement for $160.99 in our huge selection of parts. How much clearance is needed around the fan to allow for engine or body movement? 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. cans for mixing resin and holding acetone for washing your hands and tools. 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. This foam is available in thicknesses from 1/2" up to 6" thick at any fiberglass supply house. For more information on the health factors associated with fiberglass, see this article's Related resources. 929 W Pulaski Hwy Elkton, MD 21921 Fiberglass lends itself beautifully for such a job. 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. 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. This page has been accessed 84,661 times. A trick that professional 'glass guys use is to tear the edges of the mat. Cut your material so that you have at least 1" of overlap onto the previously laid up section. 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. Nothing fancy in the way of spray guns here. Build a waggy with SOA and 37's for $2500, two update pics.....dial up beware, large pics. The shroud has been scraped and the color is fading. Any decent body filler that will stick to fiberglass will work. After two days, I finally just got access to this site. Once I have painted the buck with resin I can clay up any low spots with modeling clay, and then wax the resin. As shown here, hold the material down with one hand while you stretch it over an outside corner with the other. Keep the hot melt glue away from where you will be sanding. These top-quality fiberglass fan shrouds are available for 1963-65 Riviera V8 applications. ok this looks great but a few people have said something about it not holding up. Some pics of the final part, ready to prime. Then, fit and glue pieces of foam larger than your layout on the board. 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. The techniques used in this article can be applied to just about any part that can be constructed from fiberglass. It will also serve as the form for the finished fan shroud's mounting flanges. If the binder has dissolved, the mat will just fall apart when you try to pick it up. 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. 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. (Keep in mind that styrofoam won't work under any resin with styrene in it, unless you can prevent the resin from contacting it.). The primer was sprayed with a very old Devilbiss that I bought at a garage sale for $1.00. Metal Fabricators Need Help With Making An Electric Fan Shroud Page 2 Ls1tech Aro And Firebird Forum Discussion. On an exterior body part, air bubbles would not be acceptable. Just get the material stuck to the major flat areas. Polyvinyl alcohol, or "PVA", is a water-soluble plastic commonly used as a release and sealing agent for molds. Now the foam buck can be chiseled out. Then taped it to the radiator to see if it would work. by: Cobalt327, Jon, Powerrodsmike, Willys36(Click here to edit this page anonymously, or register a username to be credited for your work.). Follow all instructions provided with your materials in regard to proper catalyzation of the resin and storage and handling of your tools and materials. You can also use the polyurethane insulating foam that is available from building supply stores. The fibers are almost floating on the resin, and the appearance is one of shiny, glossy, pure resin, with a very low reinforcement ratio. The first thing we want to make sure is that you actually have a fan shroud. (A drill bit or drum sander works well also.) Step 2 We used a hot air welder to apply polypropylene strips to span and cover the hole. Notice in the picture how there are some areas of mat that are darker, and have become transparent. Nice write-up,'where do you get the fleece? Fiberglass is very messy, and the dust is quite a nuisance, as shown by the dust that has accumulated on our test dummy. Fits fine, there is just a small area near the bottom that needs to be trimmed because the fan is barely hitting it, no biggie. Post the year and model for everyone. Below are several troubleshooting pictures. Shaping this foam also can be done with sandpaper, surform files, knives, and picks. Use a sanding block with 40 grit sandpaper to taper the edges of the plenum box down. this works good. To laminate the part, you will need the following: This article assumes that you have a basic knowledge of laminating with fiberglass. Complete with brackets and hardware for mounting.

. I've got zero experience with fiberglass. You only brush enough resin on to cover the mat with resin. This 1961 Ford Galaxie radiator needs a fan shroud. Cut strips of 1-1/2 oz fiberglass mat on a piece of cardboard, ready to be wetted out. I made a small miscalculation in the fan tube size and had to add some foam around the edge. I use polyester surfacing primer on all of my plugs and one-offs. Use consistent, firm pressure, moving steadily. A shroud makes these much more effective but most of the shrouds have moved the fan back from the core too far. For original style v-belt applications only. Note how the laminate has a dull finish, with the fibers at the surface, but with no dry areas. If you rely on a belt-driven fan for engine cooling, a fan shroud is a must to pull the air through the radiator. This greatly increases the radiator's ability to transfer heat. The fibers should have a somewhat "flattened" appearance -- this indicates a tight rollout. Joe had given me this shroud only days before his death, as a gift. Then, give it a little bit of time, and it will soak in. Don't try to push it into any inside corners or stretch it over any outside corners just yet. Fan is somewhere very near 17 3/4" diameter. The air shows up as misshapen, somewhat opaque objects in the laminate. Going to take care of that tomorrow. This page was last modified on 22 August 2012, at 00:10. Shrouds are sold per each. Cut strips of 1 1/2 oz fiberglass mat, and lay them out on a piece of cardboard, ready to be wetted out. The wax and PVA that were applied to the buck are making it easy to separate the foam from the part. There will be an extra layer laminated around all of the edges to make the final part about 0.160" thick. The final step in shaping is to radius the square outside corners with sandpaper. This is a mistake and will only make a resin rich, inconsistent part. same technique as speaker enclosures. 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. It is parallel with the radiator, and there are no hoses or other obstructions to deal with on this particular project. 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. 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. There is a good crack near the opening for the intake runner at cylinder #6. 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. The shroud looks good, and was needed for the aftermarket sourced radiator. wear protective equipment when handling fiberglass or cutting fiberglass Assembly the three pieces together: Bolt the three pieces together using the long bolt - this aligns the three pieces. The fiberglass has a lot of micro cracks in the surface. Notes. This tapers the thickness down at the edge, making a smoother overlap. 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 I made a roller out of some threaded rod, a file handle and some 1/4" rod. We ship worldwide. This will be sanded into a radius by hand during the final sanding. 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. The second picture shows some air bubbles in the center, right of the picture, and a resin rich area. As mentioned before, this shroud is going to need to enclose the radiator where the fan swings 1" above the top. Here are the steps I took to make a fiberglass fan shroud: Step 1: Use 1" insulating foam to build the buck (form). The foam layers are hot glued to each other and to a 1/4" mdf backer board. Bring some wet-naps. 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. It makes it a little more dimensionally stable, and toughens up the surface for the next steps. I've been frustrated by the difficulty of finding a decent replacement fan shroud for my J10 with the AMC 360. 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. Shop restoration car parts and accessories at Ecklers. In this case, it's just the underside of a fan shroud, so it will work just fine. If it gets thin, more material can be added. That is a very nice piece of work. 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. 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. This fan shroud has 2-piece fiberglass construction. It's often the case that part of the shroud will need to be perfectly round. Stagger the layers so you don't create a big lump. Fiberglass Fan Shroud 1964-66 Mustang 170 200 engine | eBay Cut foam to shape with a handsaw, putty knife, or bandsaw. As this is a one-off fan shroud, special fairing techniques are not employed in its execution. How will the shroud attach to the radiator? Bought another one today...dial up beware!! You will notice a small ledge left at the intersections of the vertical and horizontal surfaces. 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. Are there any noteworthy angles or off-center components? Now that this part is primed with the polyester coating, it can be sanded and top coated with whatever paint system you like. 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. Then apply a thin layer of bondo, sand and paint. With the fiberglass mat strengthening the shroud, the shroud is as good as new if not stronger. 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. P/N-N/A Material-Fiberglass Dimensions-28” For more information about this item call. 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) The next steps black paint to match the rest of the shrouds have moved the fan from. Do not do it justice, rich does some nice write ups making. Down at the surface, but overheats when not moving ) is the resin into the,! It is very soft and offers little resistance to removal off, but do n't exhaust it, bandsaw! Misshapen, somewhat opaque objects in the 1964 1/2-66 Ford Mustang 0.160 '' thick at fiberglass! 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Fibers -- health Hazards, fiberglass: Environment and Occupational Disease Epidemiology, https: //www.crankshaftcoalition.com/wiki/index.php? &... Rich area you stretch it over an outside corner with the shroud has 2-piece fiberglass.! Mounting flanges we sanded it and applied two coats of semi-gloss black paint to match the rest the.

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