Probably go with fiberglass mat and vinyl ester resin. The resin is also know as Marine resin, it's the standard for boat building and has a good strength to weight to cost ratio. Pouring a part would require an enclosed mold, which for something that I may sell 5-10 parts, is cost prohibitive. I'll get the mold going this weekend and then lay up a test part. I have a local guy who brought me the busted up shroud. I'll have him put the part on and see how it fits. If you were a good fabricator, you could easily make one from metal, that however is me I can beat the stuff into shape, but it wouldn't be pretty!
Well I started laying up the fan shroud mold this weekend. This has to be built in 4 pieces. So you can see the top and bottom section are being laid up first. Each piece has a flat flange built into it. Then I'll pull the flange dams off as well as the paper protecting the sides, and then lay up the side pieces. Once all four pieces are laid up, I'll drill and bolt the flanges together. Pop it off of the plug and trim it and start prep to get ready to make the first copy of the shroud :beer
Look'n like progress. I'm still in on a couple if'n they turn out nice. Where the bolt holes are can you pre drill a piece of metal and add to the inside of the layers for reinforcement? Thanks: Jim
I would most likely purchasing at least 2 fan shrouds. How many do you think will be manufactured? Thanks, Mac
Heck, I'll sell as many as I can The big thing will be to get the first new shroud out of the mold and make sure it lines up and works OK, luckily the guy that originally got me started on this project is local and I can have him check the first one out shortly :TU: This past weekend I finished up the first half of the mold and got it trimmed. I just need to clean up the area where the flanges meets the shroud and then start waxing the remaining red portion. I should get the remaining portion laid up this coming weekend. I'm real curious to see how this mold comes out. It's the most complicated mold I've made so far, having four seperate sections.
Just about there :grin: I finished laying up the mold yesterday. Big day today, First I'll drill a couple of 1/4" holes in each flange so the 4 pieces can be bolted back together. Then I'll seperate the mold from the "plug" (the patched together original) Then I can do the final trimming, see if there's any minor touch up to the mold surface. I'll post some more pic's after I pop the mold off.
Craig, you are doing a very good job! I've seen my friends start things like this and end up with flimsy junk because they did not take the time to make the mold correctly. You're doing a good job man. I'm still in for a couple of them. Jim
Thanks Jim :laugh: The mold is coming along, I rough trimmed it yesterday, now this weekend I'll do the final triming to the seperate pieces. It'll make it easier to clean up the edges, especially the two areas where the hoses pass through. Then water sand it smooth and see if there's any minor gel coat touch up.
Is that fresh resin I smell on a new reproduction unit? MMMMMMMMMMMMMMMMMMMMM Taste like chicken $$$$$$$$$$$$$$$$$$$$$$$$ LOL: Jim
Almost, I've been going out to the garage each night after work and water sanding the parts one piece at a time to get them ready for polishing this weekend. Last weekend I did a few touch ups to the mold once I had it apart. I have some work stuff to take care of the end of the month but I'm hoping to be laying up the first test shroud the last weekend of this month (as well as the next hood and a test radio bezel). :TU: At least these will be a heck of a lot easier to box and ship compared to my hood!
Well I just need to hit the new fan shroud mold with a couple of coats of mold release wax and it's ready to go. Next weekend is out but the one after that I'll lay the first new part up and then see how it fits on the vehicle.
:kodak::kodak:Installed yet? Pics? Its summer and its hot, really could use a fan shroud ray:ray:ray:ray:
