David worked for a company that was the leader in fiberglass hoods, fenders and etc for the aircooled VW. 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. We ship worldwide. 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. 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. Shrouds are sold per each. 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. That would be another good post- the fan and wiring. correct me if I'm wrong but weren't the factory ones on the waggies fiberglass. This article demonstrates one way to build a fiberglass fan shroud. This will make it easy to shape the circle, as well as cut the box section down to its proper thickness. The fiberglass has a lot of micro cracks in the surface. 10/26 This 1961 Ford Galaxie radiator needs a fan shroud. A wedge of foam was glued in to account for the tilt of the engine. Work quickly but carefully, as the resin will gradually dissolve the binder. P/N-N/A Material-Fiberglass Dimensions-28” For more information about this item call. The shroud has been scraped and the color is fading. 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. Enjoy the videos and music you love, upload original content, and share it all with friends, family, and the world on YouTube. Drill a hole through the center of the block of wood corresponding to the fan shroud depth. 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 hot melt glue gun makes gluing this foam fast and easy. Then, fit and glue pieces of foam larger than your layout on the board. The second picture shows some air bubbles in the center, right of the picture, and a resin rich area. Then taped it to the radiator to see if it would work. 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. It's often the case that part of the shroud will need to be perfectly round. 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. 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. For more information on the health factors associated with fiberglass, see this article's Related resources. Bought another one today...dial up beware!! Complete with brackets and hardware for mounting.
. There will be an extra layer laminated around all of the edges to make the final part about 0.160" thick. Brush on only enough resin to cover the mat, and then allow it to soak in. Nice write-up,'where do you get the fleece? It works better to pull the roller than to push it. I usually stretch the material, and wind up with a section of mat that I can reapply to the stretched, thinned out areas. That is a very nice piece of work. 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. Pick up the material from the wet out board and apply it to the part. Nothing fancy in the way of spray guns here. Fiberglass lends itself beautifully for such a job. 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 fan shroud is designed to enclose the core area so that when the fan is spinning, air flows through the entire surface area. Polyvinyl alcohol, or "PVA", is a water-soluble plastic commonly used as a release and sealing agent for molds. Just get the material stuck to the major flat areas. 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. Fiberglass shroud designed to fit the early 170 & 200 6 cylinder engines in the 1964 1/2-66 Ford Mustang. You wouldn't need the shroud if you just left the hood open a little bit. After sanding with 80 grit, a final sanding can be done with 120 grit. 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. 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. Post the year and model for everyone. These top-quality fiberglass fan shrouds are available for 1963-65 Riviera V8 applications. I use polyester surfacing primer on all of my plugs and one-offs. (Keep in mind that styrofoam won't work under any resin with styrene in it, unless you can prevent the resin from contacting it.). A trick that professional 'glass guys use is to tear the edges of the mat. It will also serve as the form for the finished fan shroud's mounting flanges. How will the shroud attach to the radiator? Does A Fan Shroud Make Difference. Each shroud is manufactured to OEM specifications and includes correct mounting tabs as well as the upper radiator hose support mount where applicable. Great job. 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. 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. This fan shroud has 2-piece fiberglass construction. Cut strips of 1 1/2 oz fiberglass mat, and lay them out on a piece of cardboard, ready to be wetted out. The part is still left on the foam and plywood buck because it is easier to handle during the bodywork phase. A shroud makes these much more effective but most of the shrouds have moved the fan back from the core too far. Learn how to repair a window channel, make a patch panel, chrome plate fiberglass … The fan shroud was damaged when the fan made contact with the shroud. There is no more resin on those strips than is on the others, they were wetted out earlier and have soaked up the resin. 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. Commercially made rollers of many sizes and shapes are available from most fiberglass supply houses. 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. Keep the hot melt glue away from where you will be sanding. Stretch the material over any outside corners, but don't try to fold it as it will only spring back. On an exterior body part, air bubbles would not be acceptable. 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. This will require a secondary lamination to form a return. Unlike others on the market, this comes with instructions and the nuts, bolts, washers, and screws you will need to install it. This page has been accessed 84,661 times. Brush some resin on the surface of your buck. Mdill, what would be a better material to use for making a shroud that is going to be subjected to such intense temp swings? ive made them for my hotrods, where there is no factory shroud. Any decent body filler that will stick to fiberglass will work. Drill a hole in the rad core template that corresponds to the location of the fan's center. Using PVA will make removing the foam much easier after the part is laid up. wear protective equipment when handling fiberglass or cutting fiberglass Reproduction fan shrouds are professionally manufactured to OEM specifications using either fiberglass or molded ABS plastic for a factory fit and appearance. I've got zero experience with fiberglass. Once the laminate has cured, the part can be removed from the table. 1966-1967 327 Radiator Cooling Fan Upper Repair Shroud Fiberglass. center of fan is 8 14" down from inside seam. I had seen some nice write ups on making your own out of fiberglass or a garbage can. Add this to the 'future project' list. same technique as speaker enclosures. Shaping this foam also can be done with sandpaper, surform files, knives, and picks. The first thing we want to make sure is that you actually have a fan shroud. The third picture shows another shot of a resin-rich area, and the fourth picture shows a proper resin/reinforcement ratio. 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. If you rely on a belt-driven fan for engine cooling, a fan shroud is a must to pull the air through the radiator. Exterior fabrication can be a daunting task, but it doesn't have to be if you follow these tips. 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. Fan is somewhere very near 17 3/4" diameter. Ok, boys, here's my foray into fabbing my own fiberglass fan shroud. Squeegees don't work well on fiberglass mat. It works extremely well for rolling out air bubbles in fiberglass. There are many other ways to shape your buck. There is a good crack near the opening for the intake runner at cylinder #6. Shop restoration car parts and accessories at Ecklers. 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. You only brush enough resin on to cover the mat with resin. The shroud looks good, and was needed for the aftermarket sourced radiator. 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 foam layers are hot glued to each other and to a 1/4" mdf backer board. The wax and PVA that were applied to the buck are making it easy to separate the foam from the part. Air bubbles look like clear voids, they are easily spotted when you put pressure on them as you can move them around. The dust will migrate everywhere if you don't exhaust it, or collect it. It's correct for 352 & 390 V8 With Heavy Duty Cooling Or Factory A/C. You can also use a brush, foam roller or your fingers to manipulate the air out. 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. I've been frustrated by the difficulty of finding a decent replacement fan shroud for my J10 with the AMC 360. This tapers the thickness down at the edge, making a smoother overlap. Don't try to push it into any inside corners or stretch it over any outside corners just yet. The final step in shaping is to radius the square outside corners with sandpaper. (USED) 2007 Mack CTP713, Fan Shroud. If the binder has dissolved, the mat will just fall apart when you try to pick it up. The plywood that is still sticking out from under the foam will be used to form the flat mounting flanges. As this is a one-off fan shroud, special fairing techniques are not employed in its execution. As shown here, hold the material down with one hand while you stretch it over an outside corner with the other. 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  links to the right of an article section. 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. I simply tape the top off with some masking tape, then wax the tape with some mold release wax. Cut strips of 1-1/2 oz fiberglass mat on a piece of cardboard, ready to be wetted out. 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. The fibers are almost floating on the resin, and the appearance is one of shiny, glossy, pure resin, with a very low reinforcement ratio. Fiberglass Fan Shroud 1964-66 Mustang 170 200 engine | eBay This is a mistake and will only make a resin rich, inconsistent part. Below are several troubleshooting pictures. Going to take care of that tomorrow. Step 2 We used a hot air welder to apply polypropylene strips to span and cover the hole. This foam is available in thicknesses from 1/2" up to 6" thick at any fiberglass supply house. One step that I do on these kinds of parts is to paint the buck with resin after shaping it. How much clearance is needed around the fan to allow for engine or body movement? If it gets thin, more material can be added. The primer was sprayed with a very old Devilbiss that I bought at a garage sale for $1.00. You can also use the polyurethane insulating foam that is available from building supply stores. It is the resin shrinking and pulling the fibers apart that causes that appearance. The fibers should have a somewhat "flattened" appearance -- this indicates a tight rollout. You will notice a small ledge left at the intersections of the vertical and horizontal surfaces. This page was last modified on 22 August 2012, at 00:10. Here are the steps I took to make a fiberglass fan shroud: Step 1: Use 1" insulating foam to build the buck (form). Brush some resin on the surface of your buck. Joe had given me this shroud only days before his death, as a gift. Buy JD FIBERGLASS 91275 CORVETTE FAN SHROUD 327: Fan Shrouds - Amazon.com FREE DELIVERY possible on eligible purchases It is very soft and offers little resistance to removal. Stuff like this needs to get posted over on the 'network' so it's not lost. Once the laminate has a flat mounting flanges or anywhere without adequate ventilation 's my foray into my... That can be removed from the table the fourth picture shows some air in! 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