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  #1  
Old 09-10-2012, 11:41 PM
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Woodchomper Woodchomper is offline
350 Buick
 
Join Date: Dec 17, 2002
Location: Saint Charles, Missouri
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How to build a fan shroud. Dial-up beware!

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.



Step 2: Shape the buck with sandpaper:



Step 3: Notice the tilt of the foam. A wedge of foam was glued in to account for the tilt of the engine.



Step 4: Cover the edges with foil tape.



Step 5: Wrap the buck with fleece. Staple fleece to the back of the backer board.



Step 6: Apply two coats of fiberglass resin to the fleece. I used 3M fiberglass resin from Home Depot.



Step 7: Apply three layers of 3M fiberglass mat to form and sand.



Step 8: Apply a layer of body filler and sand.



Step 9: Apply Rust-oleum sandable primer/filler and sand.



Step 10: Apply more body filler and block sand.



Step 11: Remove shroud from buck, sand, fill, sand, fill, sand, fill, sand.



Step 12: Mount brackets to radiator. Notice the shroud mounting tabs on corners.


Step 13: Paint shroud with Rust-oleum hammered metal finish.



Step 14: Mount shroud to radiator.



Step 15: Optional towing option - Mount junkyard Mercedes pusher fan to front of radiator.




Step 16: Enjoy the highway cooling that can only be obtained with a mechanical fan. Previous running temps with the Ford Taurus fan were 210 degrees. Also note I'm running a .040 over 401. You know the ones that always run hot if you bore them anything over .020.
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1991 GW 401 /727TF/NP229 /4" Skyjacker /EBL TBI /CS-144
1981 J10 401 /727TF/NP208 /6" Superlift /CS-144
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  #2  
Old 09-11-2012, 12:07 AM
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mdill mdill is offline
 
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Looks good, It will be interesting to see how it holds up. 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.

Let us know how it does.
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1977 J-10 Honcho 360-T15-D20
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  #3  
Old 09-11-2012, 12:14 AM
Blake Blake is offline
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Very nice!

GREAT Oil Pressure too!
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  #4  
Old 09-11-2012, 08:59 AM
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j2sax j2sax is offline
350 Buick
 
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Mdill, what would be a better material to use for making a shroud that is going to be subjected to such intense temp swings?

BTW, having seen this Rad/Fan/Shroud up close and personal, I can tell you Rich takes pride in a job well done and it shows! All looks better than factory and is obviously effective! Way to go big Rich!

Still think you and Del need to square off and see who is the Dominant 401 Waggie in the St Louis area!
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Jesse- Sparta, MO (Near SPfdl MO) J20 4 Door Project, Wag w/ 6" Rusty's, 33x12.5's, 360/727 (for now!), 77 J10, 80 J20, 3 80's Wags, 73 Commando, Lots of AMC Eagles, FSJ parts Rigs and parts
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  #5  
Old 09-11-2012, 09:06 AM
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That's pretty slick, thanks for posting!
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  #6  
Old 09-11-2012, 09:20 AM
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billyj7175 billyj7175 is offline
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Looks good Rich.
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I'll apologize ahead of time...my inner voice has Tourette's...
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  #7  
Old 09-11-2012, 10:52 AM
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men in black men in black is offline
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Nice job

Another use for action fleece
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  #8  
Old 09-11-2012, 11:37 AM
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Mars Mars is offline
350 Buick
 
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sweeeet!
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1981 J-10 Laredo.. mmmm bucket seats...
What I'm working on: http://www.ifsja.org/forums/vb/showt...50#post1503850
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  #9  
Old 09-11-2012, 12:26 PM
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Achilles Achilles is offline
350 Buick
 
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Nice looking Shroud>
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MODS: 2003 Durango bucket seats:
http://www.ifsja.org/forums/vb/showthread.php?t=159286
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Build Thread: http://www.ifsja.org/forums/vb/showthread.php?t=174925
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  #10  
Old 09-11-2012, 06:22 PM
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Southern Gorilla Southern Gorilla is offline
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That is awesome.
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Trailers belong behind trucks, not under them.

Why? Because nobody in the history of 'wheeling has ever said, "good thing I put those smaller tires on my rig."
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  #11  
Old 09-11-2012, 06:23 PM
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81cherokee laredo 81cherokee laredo is offline
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Nice write-up,'where do you get the fleece?
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  #12  
Old 09-11-2012, 07:33 PM
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Ghinmi Ghinmi is offline
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Saw this in person this weekend! The pictures do not do it justice, Rich does some nice work. Add this to the 'future project' list.
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  #13  
Old 09-11-2012, 07:43 PM
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j20owner j20owner is offline
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Stuff like this needs to get posted over on the 'network' so it's not lost.
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  #14  
Old 09-12-2012, 05:13 PM
jamesdart
 
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this works good. ive made them for my hotrods, where there is no factory shroud. 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. same technique as speaker enclosures.
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  #15  
Old 09-12-2012, 07:46 PM
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mdill mdill is offline
 
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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.
One of the reasons (the smart ones anyway) home built composite aircraft are painted white, you don't want to lose a wing taking off after sitting on the tarmac in the sun on in the south on a hot summer day.
His work looks great and I do like the idea, I am just unsure that it will hold up to real use, it might work great and last long enough in a low use application.

Quote:
Originally Posted by j2sax
Mdill, what would be a better material to use for making a shroud that is going to be subjected to such intense temp swings?

BTW, having seen this Rad/Fan/Shroud up close and personal, I can tell you Rich takes pride in a job well done and it shows! All looks better than factory and is obviously effective! Way to go big Rich!

Still think you and Del need to square off and see who is the Dominant 401 Waggie in the St Louis area!
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-----------------------------------------
Home of ADHD project list

1977 J-10 Honcho 360-T15-D20
1977 Cherokee WT 360-Th400-NP241 true-trac(s)
1979 Cherokee 4 Door 258-T-18-D20
1981 Cherokee Chief WT 360-727-NP208
1972 K20 Suburban 350 SM465 205
And the other stuff that gets driven
----------------------------------------

Last edited by mdill : 09-12-2012 at 07:50 PM.
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  #16  
Old 09-12-2012, 10:26 PM
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del del is offline
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Join Date: Apr 13, 2006
Location: ofallon,il
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shroud

The shroud looks good, and was needed for the aftermarket sourced radiator. You wouldn't need the shroud if you just left the hood open a little bit. (joke from last weekend) The idea of the pusher fan as additional cooling when needed is cool also. Post the year and model for everyone. That would be another good post- the fan and wiring. Looks good man...Del
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  #17  
Old 09-13-2012, 05:24 AM
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Brizio Brizio is offline
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Nice!
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  #18  
Old 09-13-2012, 07:05 AM
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Woodchomper Woodchomper is offline
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Join Date: Dec 17, 2002
Location: Saint Charles, Missouri
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Thanks for all the comments. After two days, I finally just got access to this site.

Quote:
Originally posted by: 81cherokee laredo
Nice write-up,'where do you get the fleece?

The fleece came from Jo-Ann fabrics. I think I was the only guy in the store that day and it felt weird.

Quote:
Originally posted by: del
The idea of the pusher fan as additional cooling when needed is cool also. Post the year and model for everyone.
Del, The fan came out of a big Mercedes probably late 80s or early 90s. I really didn't pay much attention to the vehicle when I pulled the fan. I was originally looking for a BMW E35 fan (2 speed) but the ones I found had broken blades. When I saw the Mercedes Fan I just grabbed it! One other benefit of a pusher fan is air conditioning at idle. That is as soon as I get a condenser mounted and new lines for the AC.

Quote:
Originally posted by: mdill
His work looks great and I do like the idea, I am just unsure that it will hold up to real use, it might work great and last long enough in a low use application.
Only time will tell how well this shroud will hold up. The shroud is actually about 1/4 inch thick and is fairly sturdy. Concerning the thermal breakdown temperature for polymer resins, I sent 3M an email and ask if they could provide me the specifications for their product. If in time the shroud deteriorates or cracks I'll come up with another solution. After all, it won't be the first time I fixed the same thing twice on this Jeep.

The building of this shroud only took about a week to make from start to finish. It wasn't that bad really, I would come home from work and put a coat of fiberglass on the shroud and call it a night. Part of the experience gained by this project will be used to make speaker enclosures for my son's 87 Wag.

One last word of caution, if you do a project like this read the Material Safety Data Sheet (MSDS) for the product you use. In the case of the 3M resin it is recommended to wear an organic respirator when applying the product and while sanding.
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1991 GW 401 /727TF/NP229 /4" Skyjacker /EBL TBI /CS-144
1981 J10 401 /727TF/NP208 /6" Superlift /CS-144
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  #19  
Old 09-13-2012, 07:20 AM
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manimal manimal is offline
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That is a very nice piece of work. Great job.
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  #20  
Old 09-13-2012, 07:34 AM
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3nellieb 3nellieb is offline
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ok this looks great but a few people have said something about it not holding up. correct me if I'm wrong but weren't the factory ones on the waggies fiberglass. 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.
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86 waggy fresh 360 big bore tbi and all the works fresh727/208 4:27s front locked rear spooled 4'' bjs springs and 2'' body 37s irok(as of now) lots of cuttin.
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