Make a fiberglass fan shroud

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(Finishing the part)
(Finishing the part)
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[[Image:55nice and clean.JPG|center|600px]]  
 
[[Image:55nice and clean.JPG|center|600px]]  
 
[[Image:56clean inside and out.JPG|center|600px]]
 
[[Image:56clean inside and out.JPG|center|600px]]
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As mentioned before, this shroud is going to need to enclose the radiator where the fan swings 1" above the top. This will require a seconary lamination to form a return.
  
 
[[Image:57it is hollow.JPG|center|600px]]  
 
[[Image:57it is hollow.JPG|center|600px]]  
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As the return can be flat, and on the same plane as the mounting surface, a table top will be used for the mold. I simply tape the top off with some masking tape, then wax the tape with some mold release wax. I like Partall#2, AKA "green wax".
  
 
[[Image:58tape off the table.JPG|center|600px]]  
 
[[Image:58tape off the table.JPG|center|600px]]  
  
[[Image:59lay up the return.JPG|center|600px]]  
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I just clamped the shroud to the table, then laid up 3 layers of mat.
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[[Image:59lay up the return.JPG|center|600px]]
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Once the laminate has cured, the part can be removed from the table.
  
 
[[Image:60pull the part.JPG|center|600px]]  
 
[[Image:60pull the part.JPG|center|600px]]  
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Return flange.
  
 
[[Image:61return.JPG|center|600px]]  
 
[[Image:61return.JPG|center|600px]]  
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Some pics of the final part , ready to prime.
  
 
[[Image:62finished part.JPG|center|600px]]
 
[[Image:62finished part.JPG|center|600px]]
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[[Image:65ready to prime.JPG|center|600px]]  
 
[[Image:65ready to prime.JPG|center|600px]]  
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Fancy priming rack.
  
 
[[Image:66rack for priming.JPG|center|600px]]
 
[[Image:66rack for priming.JPG|center|600px]]
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I use polyester surfacing primer on all of my plugs and one offs. Evercoat-Fiberglass Co. makes a material called "Featherfill", Poly Lux Inc makes a polyester surfacing primer, and Hawkeye industries has a line of Primers that are well suited to filling all of the pores and sandscratch marks left by shaping.
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I like the Duratec surfacing primer the best, you can build up to .040" in a single application.
  
 
[[Image:67duratec.JPG|center|600px]]
 
[[Image:67duratec.JPG|center|600px]]
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As you can see, this is a high solids primer.
 
   
 
   
 
[[Image:68this primer has some solids.JPG|center|600px]]  
 
[[Image:68this primer has some solids.JPG|center|600px]]  
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Nothing fancy in the way of spray guns here, this one is a very old Devilbiss that I bought at a garage sale for $1.00.
  
 
[[Image:Spraying primer.JPG|center|600px]]
 
[[Image:Spraying primer.JPG|center|600px]]
  
 
[[Image:Primered part.JPG|center|600px]]
 
[[Image:Primered part.JPG|center|600px]]
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Now that this part is primed with the polyester coating, it can be sanded and top coated with whichever paint system you like. 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........
  
 
===Related resources===
 
===Related resources===

Revision as of 09:36, 1 July 2007

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