Make a fiberglass fan shroud

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This in-progress article will demonstrate one way to build a fiberglass fan shroud. The techniques used in this article can be applied to just about any part that can be constructed from fiberglass.
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==Overview==
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This article demonstrates one way to build a [[Fiberglassing|fiberglass]] fan shroud. The techniques used in this article can be applied to just about any part that can be constructed from fiberglass.
  
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==The project==
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This 1961 Ford Galaxie radiator needs a fan shroud.
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{|
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|[[Image:161_starliner_radiator.JPG|thumb|left|400px|Radiator in a 1961 Ford Galaxie; needs a fan shroud]]
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|}
  
===Measurement and analysis===
 
This radiator in a 1961 Ford Galaxie needs a fan shroud.
 
  
[[Image:161_starliner_radiator.JPG|thumb|center|600px|Radiator in a 1961 Ford Galaxie, in need of a fan shroud.]]
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When we are done with this article, it will have a fan shroud that looks like this:
  
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{|
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|[[File:PICT0271-1.jpg|thumb|350px|center|]]
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|[[Image:PICT0273.JPG|thumb|350px|center|]]
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|}
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Click on any image to make it bigger.
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===Measurement and analysis===
 
Start by measuring all of the dimensions, taking care to consider all of the following:
 
Start by measuring all of the dimensions, taking care to consider all of the following:
 
#How will the shroud attach to the radiator?
 
#How will the shroud attach to the radiator?
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#What's the distance between the fan and the radiator?
 
#What's the distance between the fan and the radiator?
 
#Are there any noteworthy angles or off-center components?
 
#Are there any noteworthy angles or off-center components?
#How much clearance is needed aroung the fan to allow for engine or body movement?
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#How much clearance is needed around the fan to allow for engine or body movement?
  
For example, this fan is off-center towards the passenger side by about 1/2 inch, sets back about 1 3/8" ,and it swings about 1" above the top of the radiator. It is parallel with the radiator, and there are no hoses or other obstructions to deal with on this particular project.
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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. It is parallel with the radiator, and there are no hoses or other obstructions to deal with on this particular project.
  
[[Image:261 Starliner rad rh.JPG|thumb|center|600px|Side view of radiator in 1961 Ford Galaxie.]]
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{|
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|[[Image:261_Starliner_rad_rh.JPG|thumb|400px|left|]]
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|}
  
 
===Constructing the foam buck===
 
===Constructing the foam buck===
Using a piece of thin plywood is a good way to start on any part that has a flat mounting surface. The plywood provides a sturdy base upon which to lay out and construct the foam buck. Also it will serve as the form for the finished fan shroud's mounting flanges.
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Using a piece of thin plywood is a good way to start on any part that has a flat mounting surface. The plywood provides a sturdy base upon which to lay out and construct the foam buck. It will also serve as the form for the finished fan shroud's mounting flanges.
 
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[[Image:3start laying out.JPG|thumb|center|600px|A piece of plywood is used as a sturdy base for constructing the foam buck.]]
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[[Image:4laid out.JPG|center|600px]]
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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.
 
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.
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 foam is available in thicknesses from 1/2" up to 6" thick at any fiberglass supply house. You can also use the polyurethane insulating foam that is available from building supply stores. Just peel the foil layer off. (Keep in mind that styrofoam won't work under any resin with styrene in it, unless you can bar the resin from it.)
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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 foam is available in thicknesses from 1/2" up to 6" thick at any fiberglass supply house. You can also use the polyurethane insulating foam that is available from building supply stores. Just peel the foil layer off. (Keep in mind that styrofoam won't work under any resin with styrene in it, unless you can prevent the resin from contacting it.)
  
[[Image:7box o scrap foam.JPG|thumb|center|600px|Leftover scraps of polyurethane foam are useful for constructing a buck.]]
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{|
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|[[Image:3start laying out.JPG|thumb|330px|center|A piece of plywood is used as a sturdy base for constructing the foam buck.]]
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|[[Image:4laid out.JPG|thumb|350px|center|Correct diameter is laid out]]
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|}
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{|
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|[[Image:7box o scrap foam.JPG|thumb|330px|center|Leftover scraps of polyurethane foam are useful for constructing a buck.]]  
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|}
  
 
===Shaping and gluing the foam===
 
===Shaping and gluing the foam===
Cut foam to shape with a handsaw, putty knife, or bandsaw. Then, fit and glue pieces of foam larger than your layout on the board. A hot melt glue gun makes gluing this foam fast and easy. 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. The different glues can make sanding over seam lines difficult, as they are usually a different density and hardness than the surrounding foam.  
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Cut foam to shape with a handsaw, putty knife, or bandsaw. Then, fit and glue pieces of foam larger than your layout on the board. A hot melt glue gun makes gluing this foam fast and easy. You can also glue the foam down with an expanding urethane glue, such as [http://www.gorillaglue.com/home.htm Gorilla glue], or some of the expanding foam that comes in an aerosol can. The different glues can make sanding over seam lines difficult, as they are usually a different density and hardness than the surrounding foam.  
  
Shaping this foam also can be done with sandpaper, sureform files, knives, and picks. Even your fingers can shape this foam quite easily and rapidly.
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Shaping this foam also can be done with sandpaper, surform files, knives, and picks. Even your fingers can shape this foam quite easily and rapidly.
  
[[Image:5start foam.JPG|thumb|center|600px|The initial pieces of foam are cut and glued down to the plywood base.]]
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Keep the hot melt glue away from where you will be sanding. It is gummy and will not sand properly, making your buck a lot harder to shape than it needs to be.
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[[Image:6scribe a circle.JPG|thumb|center|600px|For the round part of the shroud, a circle is scribed in the foam.]]
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{|
 
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|-valign="top"
[[Image:8laying out the circle.JPG|thumb|center|600px|More pieces of foam are cut and glued along the scribed circle.]]
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|[[Image:5start foam.JPG|thumb|center|The initial pieces of foam are cut and glued down to the plywood base.]]
 
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|[[Image:6scribe a circle.JPG|thumb|center|For the round part of the shroud, a circle is scribed in the foam.]]
 
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|[[Image:8laying out the circle.JPG|thumb|center|More pieces of foam are cut and glued along the scribed circle.]]
Keep the hot melt glue away from where you will be sanding. It is gummy and will not sand properly, making your buck alot harder to shape than it needs to be.
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|[[Image:9it's hot melt glue.JPG|thumb|center|The glue won't sand properly, so keep it off the areas you will be sanding.]]
 
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|}
[[Image:9it's hot melt glue.JPG|thumb|center|600px|The glue won't sand properly, so keep it off the areas you will be sanding.]]
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===Forming the circular part of the shroud===
 
===Forming the circular part of the shroud===
It's often the case that part of the shroud will need to be perfectly round. If so, set up the buck with a bolt in the center, so that it can be spun by hand against an end mill. ( A drill bit or drum sander works well also.) This will make it easy to shape the circle, as well as cut the box section down to its proper thickness. There are many other ways to shape your buck. You are only limited by your imagination here.  
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It's often the case that part of the shroud will need to be perfectly round. 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. (A drill bit or drum sander works well also.) This will make it easy to shape the circle, as well as cut the box section down to its proper thickness. There are many other ways to shape your buck. You are only limited by your imagination here.  
 
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[[Image:10fast way to make a perfect circle.JPG|center|600px|A bolt centered in the buck allows it to be spun against an end mill to shape the circle.]]
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You will notice a small ledge left at the intersections of the vertical and horizontal surfaces. This will be sanded into a radius by hand during the final sanding.
 
You will notice a small ledge left at the intersections of the vertical and horizontal surfaces. This will be sanded into a radius by hand during the final sanding.
  
[[Image:11more shaping.JPG|center|600px|The buck is spun by hand to form the circular portion of the shroud shape.]]
 
 
The plywood that is still sticking out from under the foam will be used to form the flat mounting flanges.
 
The plywood that is still sticking out from under the foam will be used to form the flat mounting flanges.
 
[[Image:13roughed out some more.JPG|center|600px]]
 
  
 
Use a sanding block with 40 grit sandpaper to taper the edges of the plenum box down.  
 
Use a sanding block with 40 grit sandpaper to taper the edges of the plenum box down.  
  
[[Image:14edge detail.JPG|center|600px]]
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{|
 
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|-valign="top"
I made a small miscalculation in the fan tube size and had to add some foam around the edge. The final step in shaping is to radius the square outside corners with sandpaper. You are looking at the bottom of the shroud in this picture.
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|[[Image:10fast way to make a perfect circle.JPG|thumb|center|A bolt centered in the buck allows it to be spun against an end mill to shape the circle.]]
 
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|[[Image:11more shaping.JPG|thumb|center|The buck is spun by hand to form the circular portion of the shroud shape.]]
[[Image:15final shape.JPG|center|600px]]
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|[[Image:13roughed out some more.JPG|thumb|center]]
 
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|[[Image:14edge detail.JPG|thumb|center]]
Looking from the right side.
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|}
 
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[[Image:16more final shape.JPG|center|600px]]
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Looking from the left side.
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I made a small miscalculation in the fan tube size and had to add some foam around the edge. The final step in shaping is to radius the square outside corners with sandpaper.
  
[[Image:18even still more final shape.JPG|center|600px]]  
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{|
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|-valign="top"
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|[[Image:15final shape.JPG|thumb|center|The bottom of the shroud.]]
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|[[Image:16more final shape.JPG|thumb|center|The right side of the shroud.]]
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|[[Image:18even still more final shape.JPG|thumb|center|The left side of the shroud.]]
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|}
  
 
One step that I do on these kinds of parts is to paint the buck with resin after shaping it. It makes it a little more dimensionally stable, and toughens up the surface for the next steps.
 
One step that I do on these kinds of parts is to paint the buck with resin after shaping it. It makes it a little more dimensionally stable, and toughens up the surface for the next steps.
  
[[Image:19paint with resin.JPG|thumb|center|600px|When shaping is complete, the buck is painted with resin.]]
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Once I have painted the buck with resin I can clay up any low spots with modeling clay, and then wax the resin. I then spray a coating of polyvinyl alcohol on the waxed surface. Polyvinyl alcohol, or "PVA", is a water-soluble plastic commonly used as a release and sealing agent for molds. Using PVA will make removing the foam much easier after the part is laid up.
  
Once I have painted the buck with resin I can clay up any low spots with modeling clay, and then wax the resin. I then spray a coating of polyvinyl alchohol on the waxed surface. Polyvinyl alcohol, or "PVA", is a water-soluble plastic commonly used as a release and sealing agent for molds. Using PVA will make removing the foam much easier after the part is laid up.
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{|
 
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|-valign="top"
[[Image:20wax and PVA.JPG|center|600px]]
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|[[Image:19paint with resin.JPG|thumb|center|When shaping is complete, the buck is painted with resin.]]
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|[[Image:20wax and PVA.JPG|thumb|center]]
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|}
  
 
===Laminating the part===
 
===Laminating the part===
You will need some china bristle brushes, acetone, cans for mixing resin and holding acetone to wash your hands and tools in, scissors, resin, catalyst, fiberglass mat, cardboard and latex gloves.
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To laminate the part, you will need the following:
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*china bristle brushes
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*acetone
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*cans for mixing resin and holding acetone for washing your hands and tools
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*scissors
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*resin
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*catalyst
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*fiberglass mat
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*cardboard
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*latex gloves
  
As the scope of this article is primarily intended to show one way to construct a part using the foam buck method, it will assume that you have a basic knowledge of laminating with fiberglass. Follow all instructions provided with your materials in regard to proper catalyzation of the resin and storage and handling of your tools and materials.
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This article assumes that you have a basic knowledge of laminating with [[Fiberglassing|fiberglass]]. Follow all instructions provided with your materials in regard to proper catalyzation of the resin and storage and handling of your tools and materials.
  
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Cut strips of 1-1/2 oz fiberglass mat on a piece of cardboard, ready to be wetted out. 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. There will be an extra layer laminated around all of the edges to make the final part about 0.160" thick.
  
Cut strips of 1 1/2 oz fiberglass mat on a peice of cardboard, ready to be wetted out. 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. There will be an extra layer laminated around all of the edges to make the final part about 0.160" thick.
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When wetting out mat with resin, many people work the resin into the mat while it is on the wet out board. This is a mistake and will only make a resin rich, inconsistent part. You only brush enough resin on to cover the mat with resin. Then, give it a little bit of time, and it will soak in.
[[Image:21mat strips.JPG|center|600px]]
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When wetting out mat with resin, many people work the resin into the mat while it is on the wet out board. This is a mistake and will only make a resin rich, inconsistant part. You only brush enough resin on to cover the mat with resin, give it a little bit of time, it will soak in.
 
 
Notice in the picture how there are some areas of mat that are darker, and have become transparent. There is no more resin on those strips than is on the others, they were wetted out earlier and have soaked up the resin.  
 
Notice in the picture how there are some areas of mat that are darker, and have become transparent. There is no more resin on those strips than is on the others, they were wetted out earlier and have soaked up the resin.  
[[Image:22wetting out strips.JPG|center|600px]]
 
  
You do need to be somewhat swift with this part of the laminating process, 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. If the binder has dissolved, the mat will just fall apart when you try to pick it up..
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You do need to be somewhat swift with this part of the laminating process. 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. If the binder has dissolved, the mat will just fall apart when you try to pick it up.
  
[[Image:23wetting out some more.JPG|center|600px]]
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{|
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|-valign="top"
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|[[Image:21mat strips.JPG|center|thumb|Cut strips of 1 1/2 oz fiberglass mat, and lay them out on a piece of cardboard, ready to be wetted out.]]
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|[[Image:22wetting out strips.JPG|center|thumb|Brush on only enough resin to cover the mat, and then allow it to soak in.]]
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|[[Image:23wetting out some more.JPG|center|thumb|Work quickly but carefully, as the resin will gradually dissolve the binder.]]
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|}
  
Brush some resin on the surface of your buck. Brush a bit more resin in the corners and outside corners as these areas tend to be a little dry after stretching the mat over them.
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Brush some resin on the surface of your buck. 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.
  
[[Image:24wetting surface.JPG|center|600px]]  
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{|
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|-valign="top"
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|[[Image:24wetting surface.JPG|center|thumb|Brush the resin onto the surface of the buck.]]  
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|[[Image:25wetting out buck.JPG|center|thumb|Pay special attention to the corners.]]
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|}
  
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Pick up the material from the wet out board and apply it to the part. Don't try to push it into any inside corners or stretch it over any outside corners just yet. Just get the material stuck to the major flat areas.
  
[[Image:25wetting out buck.JPG|center|600px]]
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Stretch the material over any outside corners, but don't try to fold it as it will only spring back. Push the material into inside corners, stretching it as you go. If it gets thin, more material can be added. I usually stretch the material, and wind up with a section of mat that I can reapply to the stretched, thinned out areas.  
  
Pick up the material from the wet out board and apply it to the part. Don't try to push it ito any inside corners or stretch it over any outside corners just yet.  
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As shown here, hold the material down with one hand while you stretch it over an outside corner with the other. If you pull some material off the edge, you can put it back over the outside of the corner, as it has probably gotten a bit thin there anyway.
  
[[Image:Even 29more applying material.JPG|center|600px]]  
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{|
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|-valign="top"
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|[[Image:Even 29more applying material.JPG|center|thumb|Apply the wet out fiberglass board to the part.]]
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|[[Image:26applying material.JPG|center|thumb|Stretch the material over any outside corners, and push it into any inside corners.]]
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|[[Image:28stretching over corner.JPG|center|thumb|While holding the material down with one hand, stretch it over an outside corner with the other.]]
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|}
  
[[Image:26applying material.JPG|center|600px]]
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I made a roller out of some threaded rod, a file handle and some 1/4" rod. It works extremely well for rolling out air bubbles in fiberglass. 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. Air bubbles look like clear voids, they are easily spotted when you put pressure on them as you can move them around."Dry" spots will show up as white strands of fiberglass that spring up out of the resin.
  
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Use consistent, firm pressure, moving steadily. It works better to pull the roller than to push it.
  
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You can also use a brush, foam roller or your fingers to manipulate the air out. Squeegees don't work well on fiberglass mat. Commercially made rollers of many sizes and shapes are available from most fiberglass supply houses.
  
Stretch the material over any outside corners, don't try to fold it, it will only spring back. Push the material into inside corners, stretching it as you go. If it gets thin, more material can be added. I usually stretch the material, and wind up with a section of mat that I can reapply to the stretched, thinned out aresa.
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{|
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|-valign="top"
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|[[Image:30rolling out the air.JPG|center|thumb|A roller can be made from threaded rod, a file handle, and 1/4" rod.]]
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|[[Image:31rolling out some more air.JPG|center|thumb|You can see the difference between a rolled-out area with no air, and an area that still has air in it.]]
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|[[Image:32dwell in the corners.JPG|center|thumb|When you roll into a corner, dwell there with the roller for a second, to allow the air to come out of the corner.]]
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|}
  
[[Image:28stretching over corner.JPG|center|600px]]  
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{|
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|-valign="top"
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|[[Image:33rolling over the apex of the radius.JPG|center|thumb|Roll over a corner, not parallel with it.]]
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|[[Image:34all air is rolled out.JPG|center|thumb|Now all the air is rolled out.]]
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|[[Image:35rolled out.JPG|center|thumb]]
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|[[Image:36corner detail.JPG|center|thumb|A properly rolled-out corner.]]
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|}
  
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Cut your material so that you have at least 1" of overlap onto the previously laid up section. Stagger the layers so you don't create a big lump. A trick that professional 'glass guys use is to tear the edges of the mat. This tapers the thickness down at the edge, making a smoother overlap. 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.
  
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{|
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|-valign="top"
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|[[Image:37sizing up some mat.JPG|center|thumb]]
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|[[Image:38more wetting it out.JPG|center|thumb]]
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|[[Image:39resin in the sun shiney light.JPG|center|thumb]]
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|[[Image:40all laid up.JPG|center|thumb]]
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|}
  
I made a roller out of some threaded rod, a file handle and some 1/4 rod. It works extremely well for rolling out air bubbles in fiberglass. Move slowly, applying enough pressure to roll the air out, but not so much pressure that you move the mat around of push all of the air bubbles out. Air bubbles look like clear voids, they are easily spotted when you put pressure on them as you can move them around."Dry" spots will show up as white strands of fiberglass that spring up out of the resin.
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==Troubleshooting tips==
You can use a brush, foam roller or your fingers to manipulate the air out. Squeegees don't work well on mat. Commercially made rollers of many sizes and shapes are  available from most fiberglass supply houses.
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[[Image:30rolling out the air.JPG|center|600px]]
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Below are several troubleshooting pictures. 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. It is the resin shrinking and pulling the fibers apart that causes that appearance.  
  
You can see the difference between a rolled out area with no air, and an area that has air in it and is not laid down properly.
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The second picture shows some air bubbles in the center, right of the picture, and a resin rich area. 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 air shows up as misshapen, somewhat opaque objects in the laminate. On an exterior body part, air bubbles would not be acceptable. In this case, it's just the underside of a fan shroud, so it will work just fine. The air bubbles can be ground out, and filled.
  
[[Image:31rolling out some more air.JPG|center|600px]]
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The third picture shows another shot of a resin-rich area, and the fourth picture shows a proper resin/reinforcement ratio. Note how the laminate has a dull finish, with the fibers at the surface, but with no dry areas. The fibers should have a somewhat "flattened" appearance -- this indicates a tight rollout.
  
When you roll into a corner, dwell there with the roller for a second. This will allow the air to come out of the corner.
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{|
[[Image:32dwell in the corners.JPG|center|600px]]
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|-valign="top"
 
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|[[Image:41slightly stressed from shrinking too fast.JPG|center|thumb|Slightly stressed from shrinking too fast in the sun.]]
Roll over a corner, not parallel with it.
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|[[Image:42close up of resin rich and air bubbles.JPG|center|thumb|Air bubbles, and a resin-rich area.]]
[[Image:33rolling over the apex of the radius.JPG|center|600px]]
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|[[Image:43resin rich.JPG|center|thumb|Resin-rich area.]]
 
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|[[Image:44good resin glass ratio.JPG|center|thumb|Proper resin/reinforcement ratio and rollout.]]
[[Image:34all air is rolled out.JPG|center|600px]]
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|}
 
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[[Image:35rolled out.JPG|center|600px]]
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[[Image:36corner detail.JPG|center|600px]]
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[[Image:37sizing up some mat.JPG|center|600px]]
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[[Image:38more wetting it out.JPG|center|600px]]
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[[Image:39resin in the sun shiney light.JPG|center|600px]]  
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[[Image:40all laid up.JPG|center|600px]]
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Here is a couple of troubleshooting pictures. 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. It is the resin shrinking and pulling the fibers apart that causes that appearance.
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[[Image:41slightly stressed from shrinking too fast.JPG|center|600px]]
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Here are some air bubbles, center right of the pic, and a resin rich area. 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 air shows up as misshapen, somewhat opaque objects in the laminate.
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This would not be acceptable to me on an exterior body part, in this case it is the underside of a fan shroud, and will work just fine. The air bubbles can be ground out, and filled.
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[[Image:42close up of resin rich and air bubbles.JPG|center|600px]]
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Resin rich, again.
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[[Image:43resin rich.JPG|center|600px]]
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An indication of a good resin/reinforcement ratio is shown in this picture, the laminate has a dull finish, with the fibers at the surface, but with no dry areas. The fibers should have a somewhat "flattened" appearance, this indicates a tight rollout.
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[[Image:44good resin glass ratio.JPG|center|600px]]
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===Trimming the part===  
 
===Trimming the part===  
I use a diamond saw on a die grinder to trim parts, you can use a grinder with a 24 grit disc or sawzall just as easily.  
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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.  
  
[[Image:44trimming the excess.JPG|center|600px]]  
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Fiberglass is very messy, and the dust is quite a nuisance, as shown by the dust that has accumulated on our test dummy. 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. Use of a minimum N95 dust mask, and proper eye and body protection is a must. Don't do this in your house, or anywhere without adequate ventilation. The dust will migrate everywhere if you don't exhaust it, or collect it. For more information on the health factors associated with fiberglass, see this article's [[#Related_resources|Related resources]].
  
All trimmed, ground and ready for some body filler.
 
  
[[Image:45trimmed part.JPG|center|600px]]  
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{|
Fiberglass is very messy, and the dust is quite a nuisance, as shown by the dust that has accumulated on our test dummy. Use of a minimum N95 dust mask, and proper eye and body protection is a must. Don't do this in your house, or anywhere without adequate ventilation.
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|-valign="top"
The dust will migrate everywhere if you don't exhaust it, or collect it.
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|[[Image:44trimming the excess.JPG|center|thumb|Trimming off the excess with a diamond saw on a die grinder.]]
It is considered by some to be harmful, take appropriate measures to keep it safe.
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|[[Image:45trimmed part.JPG|center|thumb|All trimmed, ground, and ready for some body filler.]]
 +
|[[Image:46trimmed part with a fat boy.JPG|center|thumb|Use a dust mask, and proper eye and body protection when working with fiberglass dust.]]
 +
|}
  
 +
===Finishing the part===
 +
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. Any decent body filler that will stick to fiberglass will work. 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 part is still left on the foam and plywood buck because it is easier to handle during the bodywork phase.
  
[[Image:46trimmed part with a fat boy.JPG|center|600px]]
+
As this is a one-off fan shroud, special fairing techniques are not employed in its execution. 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.
  
===Finishing the part===
+
{|
 +
|-valign="top"
 +
|[[Image:49even more bondo.JPG|center|thumb|Leave the part on the buck for ease of handling.]]
 +
|[[Image:47skim coat of bondo.JPG|center|thumb|Apply a skim coat of bondo.]]
 +
|[[Image:48more bondo.JPG|center|thumb|Some areas need another coat to level the surface.]]
 +
|}
  
[[Image:49even more bondo.JPG|center|600px]]
+
After sanding with 80 grit, a final sanding can be done with 120 grit.
  
[[Image:47skim coat of bondo.JPG|center|600px]]
+
{|
 +
|-valign="top"
 +
|[[Image:50after sanding.JPG|center|thumb|After sanding with 80 grit.]]  
 +
|[[Image:51after more sanding.JPG|center|thumb|After sanding with 120 grit.]]
 +
|}
  
[[Image:48more bondo.JPG|center|600px]]
+
Now the foam buck can be chiseled out. It is very soft and offers little resistance to removal. The wax and PVA that were applied to the buck are making it easy to separate the foam from the part. Most of it just pops right off, but a blow gun can be used to remove the smaller flakes.
  
 +
{|
 +
|-valign="top"
 +
|[[Image:52chipping out rocks.JPG|center|thumb|Chiseling out the larger pieces of foam.]]
 +
|[[Image:53most of the foam out.JPG|center|thumb|Most of the foam is now out.]]
 +
|[[Image:55nice and clean.JPG|center|thumb|Nice and clean.]]
 +
|[[Image:56clean inside and out.JPG|center|thumb|Clean inside and out.]]
 +
|}
  
 +
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 secondary lamination to form a return. 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 [http://www.rexco-usa.com/part3.htm Partall #2], aka "green wax".
  
[[Image:50after sanding.JPG|center|600px]]
+
Just clamp the shroud to the table, and lay up 3 layers of fiberglass mat.
  
[[Image:51after more sanding.JPG|center|600px]]  
+
{|
 +
|-valign="top"
 +
|[[Image:57it is hollow.JPG|center|thumb|The shroud requires a secondary lamination.]]
 +
|[[Image:58tape off the table.JPG|center|thumb|Taping off the table.]]
 +
|[[Image:59lay up the return.JPG|center|thumb|Laying up the return.]]
 +
|}
  
[[Image:52chipping out rocks.JPG|center|600px]]
+
Once the laminate has cured, the part can be removed from the table.  
  
[[Image:53most of the foam out.JPG|center|600px]]
+
{|
 +
|-valign="top"
 +
|[[Image:60pull the part.JPG|center|thumb|Removing the part from the table.]]
 +
|[[Image:61return.JPG|center|thumb|The return flange.]]
 +
|}
  
[[Image:55nice and clean.JPG|center|600px]]
+
Some pics of the final part, ready to prime.
[[Image:56clean inside and out.JPG|center|600px]]
+
  
[[Image:57it is hollow.JPG|center|600px]]  
+
{|
 +
|-valign="top"
 +
|[[Image:62finished part.JPG|center|thumb]]
 +
|[[Image:64backside.JPG|center|thumb]]
 +
|[[Image:65ready to prime.JPG|center|thumb]]
 +
|[[Image:66rack for priming.JPG|center|thumb|The part is placed on a simple priming rack.]]
 +
|}
  
[[Image:58tape off the table.JPG|center|600px]]  
+
I use polyester surfacing primer on all of my plugs and one-offs. Evercoat-Fiberglass Co. makes a material called [http://www.evercoat.com/productDetail.aspx?pID=171 Featherfill], Poly-Lux, Inc. makes a polyester surfacing primer, and [http://www.duratec1.com/ProductList.html 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.
  
[[Image:59lay up the return.JPG|center|600px]]  
+
I like the [http://www.duratec1.com/dp04.html Duratec surfacing primer] the best, because you can build up to 0.040" in a single application.
  
[[Image:60pull the part.JPG|center|600px]]  
+
{|
 +
|-valign="top"
 +
|[[Image:67duratec.JPG|center|thumb|The Duratec polyester surfacing primer.]]
 +
|[[Image:68this primer has some solids.JPG|center|thumb|As you can see, this is a high solids primer.]]
 +
|}
  
[[Image:61return.JPG|center|600px]]
+
Nothing fancy in the way of spray guns here. The primer was sprayed with a very old Devilbiss that I bought at a garage sale for $1.00.
  
[[Image:62finished part.JPG|center|600px]]
+
{|
 +
|-valign="top"
 +
|[[Image:Spraying primer.JPG|center|thumb|Spraying the primer.]]
 +
|[[Image:Primered part.JPG|center|thumb|The part is now primed.]]
 +
|}
  
[[Image:64backside.JPG|center|600px]]
+
Now that this part is primed with the polyester coating, it can be sanded and top coated with whatever paint system you like.
  
[[Image:65ready to prime.JPG|center|600px]]
+
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...
  
[[Image:66rack for priming.JPG|center|600px]]
+
===Related articles===
 +
*[[Fiberglassing]]
  
[[Image:67duratec.JPG|center|600px]]
+
===External links===
+
*[http://en.wikipedia.org/wiki/Polyvinyl_alcohol Polyvinyl Alcohol], ''Wikipedia'', retrieved June 26, 2007.
[[Image:68this primer has some solids.JPG|center|600px]]  
+
*[http://www.osha.gov/SLTC/syntheticmineralfibers/recognition.html Synthetic Mineral Fibers -- Health Hazards], ''US Department of Labor, Occupational Safety and Health Administration (OSHA)'', retrieved June 26, 2007.
 +
*[http://en.wikipedia.org/wiki/Fiberglass Fiberglass], ''Wikipedia'', retrieved June 26, 2007.
 +
*[http://www.lungusa.org/site/pp.asp?c=dvLUK9O0E&b=35439 Facts About Fiberglass], ''American Lung Association'', retrieved June 26, 2007.
 +
*[http://www.nyc.gov/html/doh/html/epi/fiberglass-fact.shtml Fiberglass: Environment and Occupational Disease Epidemiology], ''New York City Department of Health and Mental Hygiene'', retrieved June 26, 2007.
  
[[Image:Spraying primer.JPG|center|600px]]
+
[[Category:Cooling]]
 +
[[Category:Engine]]
 +
[[Category:Good articles]]
  
[[Image:Primered part.JPG|center|600px]]
+
{{youcanedit}}

Latest revision as of 01:10, 22 August 2012

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