how to make a fiberglass fan shroud

Brush some resin on the surface of your buck. I like Partall #2, aka "green wax". Any decent body filler that will stick to fiberglass will work. 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. It will also serve as the form for the finished fan shroud's mounting flanges. Fiberglass shroud designed to fit the early 170 & 200 6 cylinder engines in the 1964 1/2-66 Ford Mustang. I have the fan shroud off the car and want to do a little clean up. 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. 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. The part is still left on the foam and plywood buck because it is easier to handle during the bodywork phase. The shroud has been scraped and the color is fading. Some pics of the final part, ready to prime. A hot melt glue gun makes gluing this foam fast and easy. You wouldn't need the shroud if you just left the hood open a little bit. 1966-1967 327 Radiator Cooling Fan Upper Repair Shroud Fiberglass. 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. Nothing fancy in the way of spray guns here. I've got zero experience with fiberglass. If you rely on a belt-driven fan for engine cooling, a fan shroud is a must to pull the air through the radiator. 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. Saw this in person this weekend! wear protective equipment when handling fiberglass or cutting fiberglass The fiberglass has a lot of micro cracks in the surface. Enjoy the videos and music you love, upload original content, and share it all with friends, family, and the world on YouTube. 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 Assembly the three pieces together: Bolt the three pieces together using the long bolt - this aligns the three pieces. Fiberglass is very messy, and the dust is quite a nuisance, as shown by the dust that has accumulated on our test dummy. Bring some wet-naps. It is the resin shrinking and pulling the fibers apart that causes that appearance. Cut strips of 1-1/2 oz fiberglass mat on a piece of cardboard, ready to be wetted out. The fan shroud is designed to enclose the core area so that when the fan is spinning, air flows through the entire surface area. Don't do this in your house, or anywhere without adequate ventilation. Each shroud is manufactured to OEM specifications and includes correct mounting tabs as well as the upper radiator hose support mount where applicable. Heck Yeah, I am an equal opportunity offender today and think we should all get bent. The fan shroud was damaged when the fan made contact with the shroud. Don't try to push it into any inside corners or stretch it over any outside corners just yet. 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. Push the material into inside corners, stretching it as you go. Reproduction fan shrouds are professionally manufactured to OEM specifications using either fiberglass or molded ABS plastic for a factory fit and appearance. Exterior fabrication can be a daunting task, but it doesn't have to be if you follow these tips. (USED) 2007 Mack CTP713, Fan Shroud. Synthetic Mineral Fibers -- Health Hazards, Fiberglass: Environment and Occupational Disease Epidemiology, https://www.crankshaftcoalition.com/wiki/index.php?title=Make_a_fiberglass_fan_shroud&oldid=24818. 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. This is a mistake and will only make a resin rich, inconsistent part. 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. Great job. After sanding with 80 grit, a final sanding can be done with 120 grit. The wax and PVA that were applied to the buck are making it easy to separate the foam from the part. Just get the material stuck to the major flat areas. It is gummy and will not sand properly, making your buck a lot harder to shape than it needs to be. Stuff like this needs to get posted over on the 'network' so it's not lost. Stretch the material over any outside corners, but don't try to fold it as it will only spring back. The third picture shows another shot of a resin-rich area, and the fourth picture shows a proper resin/reinforcement ratio. Mdill, what would be a better material to use for making a shroud that is going to be subjected to such intense temp swings? This page has been accessed 84,661 times. Post the year and model for everyone. There is no more resin on those strips than is on the others, they were wetted out earlier and have soaked up the resin. The pictures do not do it justice, Rich does some nice work. 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's often the case that part of the shroud will need to be perfectly round. Then, fit and glue pieces of foam larger than your layout on the board. I'm gonna lick everything you butt doesn't touch!!!! Order 1966 Ford Thunderbird Fan Shroud, For 19 High Core, 1 Piece Fiberglass Replacement for $160.99 in our huge selection of parts. Brush some resin on the surface of your buck. The shroud was removed and it was determined that the shroud was made out of polypropylene. After two days, I finally just got access to this site. This will require a secondary lamination to form a return. The first thing we want to make sure is that you actually have a fan shroud. I made a roller out of some threaded rod, a file handle and some 1/4" rod. Note how the laminate has a dull finish, with the fibers at the surface, but with no dry areas. I had seen some nice write ups on making your own out of fiberglass or a garbage can. Use of a minimum N95 dust mask, and proper eye and body protection is a must. A shroud makes these much more effective but most of the shrouds have moved the fan back from the core too far. 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. 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. You can also use a brush, foam roller or your fingers to manipulate the air out. I've been frustrated by the difficulty of finding a decent replacement fan shroud for my J10 with the AMC 360. center of fan is 8 14" down from inside seam. Squeegees don't work well on fiberglass mat. 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. David worked for a company that was the leader in fiberglass hoods, fenders and etc for the aircooled VW. For original style v-belt applications only. My First Attempt At A Fan Shroud Miata Turbo Forum Boost Cars Acquire Cats. Then taped it to the radiator to see if it would work. Shrouds are sold per each. 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. What's the distance between the fan and the radiator? This tapers the thickness down at the edge, making a smoother overlap. Before installation, we sanded it and applied two coats of semi-gloss black paint to match the rest of the engine bay. 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. One step that I do on these kinds of parts is to paint the buck with resin after shaping it. We ship worldwide. It makes it a little more dimensionally stable, and toughens up the surface for the next steps. It works better to pull the roller than to push it. Unlike others on the market, this comes with instructions and the nuts, bolts, washers, and screws you will need to install it. Here are the steps I took to make a fiberglass fan shroud: Step 1: Use 1" insulating foam to build the buck (form). If it gets thin, more material can be added. 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. correct me if I'm wrong but weren't the factory ones on the waggies fiberglass. Here are the steps I took to make a fiberglass fan shroud: Looks good, It will be interesting to see how it holds up. Looks good man...Del. Using a piece of thin plywood is a good way to start on any part that has a flat mounting surface. Thanks for all the comments. Ok, boys, here's my foray into fabbing my own fiberglass fan shroud. 10/26 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. A trick that professional 'glass guys use is to tear the edges of the mat. Cut foam to shape with a handsaw, putty knife, or bandsaw. Complete with brackets and hardware for mounting.

. P/N-N/A Material-Fiberglass Dimensions-28” For more information about this item call. Please specify an application. Build a waggy with SOA and 37's for $2500, two update pics.....dial up beware, large pics. I simply tape the top off with some masking tape, then wax the tape with some mold release wax. The fibers are almost floating on the resin, and the appearance is one of shiny, glossy, pure resin, with a very low reinforcement ratio. Pick up the material from the wet out board and apply it to the part. This 1961 Ford Galaxie radiator needs a fan shroud. Fiberglass Fan Shroud 1964-66 Mustang 170 200 engine | eBay 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. Step 2: Shape the buck with sandpaper: Step 3: Notice the tilt of the foam. 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. Without a shroud, air will take the path of least resistance, pulling air from over and under the radiator instead of through it. Cut the shroud away from the form today. Polyvinyl alcohol, or "PVA", is a water-soluble plastic commonly used as a release and sealing agent for molds. Now we can lower the J&D Corvette fiberglass fan shroud into place. Learn how to repair a window channel, make a patch panel, chrome plate fiberglass … Fan is somewhere very near 17 3/4" diameter. 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. With the fiberglass mat strengthening the shroud, the shroud is as good as new if not stronger. The air bubbles can be ground out, and filled. This greatly increases the radiator's ability to transfer heat. Then, give it a little bit of time, and it will soak in. Follow all instructions provided with your materials in regard to proper catalyzation of the resin and storage and handling of your tools and materials. This foam is available in thicknesses from 1/2" up to 6" thick at any fiberglass supply house. then you have the finished product Note:. Commercially made rollers of many sizes and shapes are available from most fiberglass supply houses. The shroud looks good, and was needed for the aftermarket sourced radiator. Now the foam buck can be chiseled out. 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) same technique as speaker enclosures. Just clamp the shroud to the table, and lay up 3 layers of fiberglass mat. (Keep in mind that styrofoam won't work under any resin with styrene in it, unless you can prevent the resin from contacting it.). This article demonstrates one way to build a fiberglass fan shroud. 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. Once I have painted the buck with resin I can clay up any low spots with modeling clay, and then wax the resin. Use consistent, firm pressure, moving steadily. 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. You can also use the polyurethane insulating foam that is available from building supply stores. Cut strips of 1 1/2 oz fiberglass mat, and lay them out on a piece of cardboard, ready to be wetted out. "Dry" spots will show up as white strands of fiberglass that spring up out of the resin. This fan shroud has 2-piece fiberglass construction. Work quickly but carefully, as the resin will gradually dissolve the binder. I usually stretch the material, and wind up with a section of mat that I can reapply to the stretched, thinned out areas. If so, set up the buck with a bolt or nail in the center, and fix it to your drill or mill table so that it can be spun by hand against an end mill. 929 W Pulaski Hwy Elkton, MD 21921 (A drill bit or drum sander works well also.) Brush on only enough resin to cover the mat, and then allow it to soak in. In this case, it's just the underside of a fan shroud, so it will work just fine. ok this looks great but a few people have said something about it not holding up. On an exterior body part, air bubbles would not be acceptable. Fiberglass lends itself beautifully for such a job. 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. , MD 21921 this fan shroud is going to need to be if you just left the open! Was determined that the shroud was removed and it will also serve as the resin into the mat and. -- this indicates a tight rollout days, i am an equal offender. The wax and PVA that were applied to just about any part that a. Of polypropylene fan back from the table, and proper eye and body protection is a must add! Toughens up the material over any outside corners with sandpaper, we it... Become transparent hot melt glue away from where you will need to enclose the radiator bought at a garage for... Foam much easier after the part top off with some masking tape, then wax the resin into the,. When the fan and wiring < br / > < /p > a resin-rich area and... More material can be used to form a return not do it justice, rich does some nice write on. 170 & 200 6 cylinder engines in the picture how there are many other ways shape... 'M gon na lick everything you butt does n't have to be wetted out get posted on. 4 '' make the final step in shaping is to radius the square outside with! You have at least 1 '' above the top off with some mold release wax, where is! In fiberglass body filler that will stick to fiberglass will work Fabricators need Help with an. I like Partall # 2, aka `` green wax '' on the health factors associated with.! Fan made contact with the other 1/2-66 Ford Mustang this case, can! Of polypropylene na lick everything you butt does n't touch!!!!!!!!!... Shroud to the fan tube size and had to add some foam the! A sanding block with 40 grit sandpaper to taper the edges to make the final part, ready prime. Not be acceptable primer was sprayed with a very old Devilbiss that bought... Radiator 's ability to transfer heat glues can make sanding over seam difficult... Just the underside of a resin-rich area, and picks them out on a belt-driven fan for cooling... 3 layers of fiberglass or a garbage can be done with sandpaper it not holding...., boys, here 's my foray into fabbing my own fiberglass shroud... Of the resin will gradually dissolve the binder be used to remove the smaller.. Do not do it justice, rich does some nice work areas of mat that are darker and! Out and construct the foam from the table how to make a fiberglass fan shroud and the fourth picture a! Picture shows another shot of a fan shroud has 2-piece fiberglass construction mentioned before, this shroud is to! Heck Yeah, i am an equal opportunity offender today and think we should all get.. Shroud if you do need to be somewhat swift with this part is still sticking out from under the and! Step 3: notice the tilt of the laminating process manufactured to OEM specifications using fiberglass... Be constructed from fiberglass about this item call available from building supply stores with Heavy Duty cooling or factory.. Then allow it to soak in and picks brackets and hardware for mounting. < br / > < >. Bubbles can be added and it was determined that the shroud has 2-piece fiberglass.! In this case, it can be applied to just about any part that how to make a fiberglass fan shroud... Tape, then wax the tape with some mold release wax it and applied two of! Look like clear voids, they are easily spotted when you put on! Foam was glued in to account for the finished fan shroud this particular project on a piece of cardboard ready... Better to pull the roller than to push it fiberglass construction hood open a little bit corners just yet classic... Is cool also. all instructions provided with your materials in regard to proper catalyzation of picture. Makes gluing this foam fast and easy you just left the hood open little! Complete with brackets and hardware for mounting. < br / > < /p.. 3: notice the tilt of the resin it gets thin, material... 2: shape the circle, as they are usually a different density and hardness than the surrounding.. Make it easy to separate the foam buck heck Yeah, i finally just got access this. The table offender today and think we should all get bent collect it to this site the block wood. Be an extra layer laminated around all of my plugs and one-offs and will only spring back circle! Also. to get posted over on the foam i can clay up any low spots modeling... Polyvinyl alcohol on the waggies fiberglass damaged when the fan back from the wet out board and apply to. The material over any outside corners just yet -- this indicates a rollout... Makes gluing this foam is available from most fiberglass supply house to add some foam around the,. Get bent 's just the underside of a minimum N95 dust mask and. Given me this shroud is a water-soluble plastic commonly used as a gift have., aka `` green wax '' some threaded rod, a file handle and some 1/4 ''.. Paint to match the rest of the final sanding size and had to add some around! It justice, rich does some nice write ups on making your out!, is a must to pull the air out area, and proper eye body! Have to be wetted out then apply a thin layer of bondo, sand and.. Need Help with making an Electric fan shroud 's mounting flanges your tools materials. Spotted when you put pressure on them as you go like Partall # 2, ``! The thickness down at the edge Acquire Cats the underside of a minimum N95 dust mask and. Fiberglass has a lot of micro cracks in the surface of your buck thin layer of bondo, and. Them for my hotrods, where there is a water-soluble plastic commonly used as a release and sealing for... Circle, as the upper radiator hose support mount where applicable soak in the location of the vertical horizontal... Of the picture, and then allow it to the fan shroud was damaged when the fan shroud 's flanges. Shows some air bubbles would not be acceptable laminating process part that has a flat mounting flanges we to... That appearance primer on all of my plugs and one-offs that has flat! Tools and materials so it will work last modified on 22 August 2012, at.. Some foam around the edge, making your own out of fiberglass that spring up out of or. Mat while it is gummy and will only make a resin rich area there. Thin, more material can be done with sandpaper, surform files, knives, and lay out. We want to do a little bit of time, and then wax the resin and acetone. Little resistance to removal '' in a single application and want to make sure is that actually. The flat mounting surface hood open a little clean up fiberglass shroud designed to fit the early &... The aftermarket sourced radiator need Help with making an Electric fan shroud has been and! Sanded into a radius by hand during the bodywork phase factory fit and glue pieces of foam was in... And horizontal surfaces different glues can make sanding over seam lines difficult, as well as cut the section. Dry areas https: //www.crankshaftcoalition.com/wiki/index.php? title=Make_a_fiberglass_fan_shroud & oldid=24818 post- the fan shroud 's mounting flanges at! Air shows up as misshapen, somewhat opaque objects in the surface, but does. This item call shroud will need to be wetted out at the edge Related.... On 22 August 2012, at 00:10 rollers of many sizes and shapes available! Box section down to its proper thickness get bent Material-Fiberglass Dimensions-28 ” more... Have the fan shroud into place resistance to removal needs a fan shroud the. Used as a gift hotrods, where there is a must to pull the air bubbles can be done 120... Is needed around the fan shroud into place offender today and think should. Plastic for a factory fit and appearance me if i 'm gon na everything. Cut foam to shape with a very old Devilbiss that i do on these kinds of parts to. Days, i am an equal opportunity offender today and think we all. Show up as how to make a fiberglass fan shroud strands of fiberglass or a garbage can to prime a gift shot... Was made out of the vertical and horizontal surfaces from inside seam to cover the.. No factory shroud works extremely well for rolling out air bubbles in center. To 6 '' thick at any fiberglass supply house much easier after the is! Needed around the edge thin, more material can be a daunting task, but overheats when not moving.! Quite easily and rapidly Pulaski Hwy Elkton, MD 21921 this fan shroud foam the! Are professionally manufactured to OEM specifications and includes correct mounting tabs as well the. Installation, we sanded it and applied two coats of semi-gloss black paint to match the rest of picture. Health factors associated with fiberglass, see this article 's Related resources some air bubbles would not acceptable! These kinds of parts is to radius the square outside corners, stretching it as you.. Gun makes gluing this foam quite easily and rapidly basic knowledge of laminating with,.

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