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jcal73 05-26-2011 07:16 AM

Building A fan Shroud CAUTION LONG AND PIC HEAVY!!
 
My little 5 is running well after the engine install last year.
We had a module problem, but other than that she runs great.
The only problem we have run into is that since the temps around here have been getting warmer, so has the jeep.
It would cool fine sitting in traffic at idle, but would overheat while going long distances at a sustained speed of over 50 mph.
At those speeds it tachs over 2000 rpm.
I could duplicate the problem sitting in the driveway and throttling it to 2200rpm and the temp would climb slowly to above 205deg.
I removed the cap and verified that I had good coolant flow.
The only other thing could be is that it doesn't have enough fan.
Here is a pic of my electric fan setup.

http://i261.photobucket.com/albums/i...ineSwap096.jpg

It has too small a fan and not enough area open for the air to get through while on the road.
I know I could have tried to make this setup better, but I didn't really want to run an electric fan (I have my reasons not up for debate).

I removed the electric setup and installed the clutch fan from my old 93 Chevy K1500 with the same engine and belt drive setup.
It ran fine on the road at speed, but would warm up at idle.
I knew it would work, it just needed a shroud.

So, I ordered these.

http://www.summitracing.com/parts/DER-17417/?rtype=10

http://www.summitracing.com/parts/DER-31547/?rtype=10

I then started doing some research on building fan shrouds.

I came across these sites.

This is an instruction on building a shroud out of fiberglass.

http://www.cadvision.com/blanchas/54...FanShroud.html

I liked the idea and did more research and found this on youtube.
It is building a speaker enclosure, but the principals are the same.


Now to gather the stuff and try to build it!



:cheers:

Jeff

jcal73 05-26-2011 07:16 AM

So I went to Hobby Lobby and purchased 2yds of fleece fabric.
I picked up some 1/4inch particle board, Fiberglass resin and matt, and some 1x2 boards at Home Depot.
Now to start building.

When you look at these pics please keep in mind that I have no experience with wood working or fiberglass!

It was learning as I went!:laugh:

Here are a few pics of my first attempt. I did not use enough resin on the fleece and my template was built incorrectly.

Building the template.

http://i261.photobucket.com/albums/i...Shroud-003.jpg

A few of the incorrect shroud build

http://i261.photobucket.com/albums/i...Shroud-004.jpg

http://i261.photobucket.com/albums/i...Shroud-005.jpg

http://i261.photobucket.com/albums/i...Shroud-007.jpg

http://i261.photobucket.com/albums/i...Shroud-008.jpg

The fist try would have contacted the fan on the bottom because of the steep angle from the radiator core to the fan opening.

The second try.
I added a half moon shape to the top and bottom of the core template.

http://i261.photobucket.com/albums/i...Shroud-009.jpg

http://i261.photobucket.com/albums/i...Shroud-010.jpg


http://i261.photobucket.com/albums/i...Shroud-011.jpg


The template is longer at the top than bottom to make up of for the tilt of the engine.
http://i261.photobucket.com/albums/i...hroud-012-.jpg

More to follow.
:cheers:

Jeff

jcal73 05-26-2011 07:16 AM

Stretched Fleece and stapled.
http://i261.photobucket.com/albums/i...Shroud-014.jpg

http://i261.photobucket.com/albums/i...Shroud-016.jpg

Again you can see the difference between the top of the shroud and bottom
To account for the angle of the fan in relation to the radiator core.

http://i261.photobucket.com/albums/i...Shroud-015.jpg

I then mixed some resin and soaked the fleece, let it dry and mixed and applied a very heavy coat.
http://i261.photobucket.com/albums/i...Shroud-017.jpg

http://i261.photobucket.com/albums/i...Shroud-018.jpg

http://i261.photobucket.com/albums/i...Shroud-019.jpg

http://i261.photobucket.com/albums/i...Shroud-020.jpg

Now to cutting out the template, glassing the inside and finishing.

:cheers:
Jeff

jcal73 05-26-2011 08:07 AM

I used my dremel tool with a router adapter and a 1/8 rotozip blade made for cutting wood to cut out the core side of the template.
http://i261.photobucket.com/albums/i...Shroud-022.jpg

I glassed the inside with two layers of glass and resin. My camera battery died and there are no pics of this, sorry.

After drying overnight I smoothed out the outside and inside with a small air grinder with a 36 grit pad.
http://i261.photobucket.com/albums/i...Shroud-024.jpg

http://i261.photobucket.com/albums/i...Shroud-025.jpg

Next I cut out the round part of the template with the dremel.
http://i261.photobucket.com/albums/i...Shroud-026.jpg

http://i261.photobucket.com/albums/i...Shroud-027.jpg

Now for a test fitting. My measurements were correct I was very happy!

http://i261.photobucket.com/albums/i...Shroud-028.jpg

http://i261.photobucket.com/albums/i...Shroud-029.jpg

I had to smooth out some places for clearance.
http://i261.photobucket.com/albums/i...Shroud-030.jpg

Now to paint finishing.
I primed the shroud.
http://i261.photobucket.com/albums/i...Shroud-032.jpg

Sanded and glazed and sanded and sanded and sanded! You get the idea!:laugh:
http://i261.photobucket.com/albums/i...Shroud-033.jpg

I sprayed it semi-gloss black.
http://i261.photobucket.com/albums/i...Shroud-036.jpg

http://i261.photobucket.com/albums/i...Shroud-037.jpg

Then I scratched it all up installing it!:rofl:
http://i261.photobucket.com/albums/i...Shroud-038.jpg

Next onto brackets and installation.

:cheers:

Jeff

jcal73 05-26-2011 08:15 AM

I made small brackets to hold the shroud in place out of some small bar flat that I had lying around.

http://i261.photobucket.com/albums/i...Shroud-039.jpg

http://i261.photobucket.com/albums/i...Shroud-040.jpg

A few pics of the finished product, well almost, I still will remove it and repaint.

http://i261.photobucket.com/albums/i...Shroud-041.jpg

http://i261.photobucket.com/albums/i...Shroud-042.jpg

http://i261.photobucket.com/albums/i...Shroud-043.jpg

This pic was taken after a 17 mile drive and letting her sit at idle for 20 minutes. I believe that my cooling problems may be gone!
http://i261.photobucket.com/albums/i...Shroud-044.jpg

:cheers:

Jeff

rixcj 05-26-2011 08:24 AM

You did a great job! Congrats!

Thanks for posting this.

Rich

CrawlingForward 05-26-2011 08:37 AM

Wow! Great write-up and a nice product!

mikeumkc 05-26-2011 09:01 AM

I absolutely LOVE your paint studio. hahaha. Awesome.

jcal73 05-26-2011 09:05 AM

Quote:

Originally Posted by mikeumkc (Post 11606580)
I absolutely LOVE your paint studio. hahaha. Awesome.

That's an old camper my dad made into a shed behind a little storage building.
He parks a 1969 John Deere 110 inside it.

Jeff

drerict 05-26-2011 09:12 AM

Looks good, I may be copy your idea for mine.

jcal73 05-26-2011 09:14 AM

Quote:

Originally Posted by drerict (Post 11606634)
Looks good, I may be copy your idea for mine.

Go ahead! I copied others to build it!:laugh:


Jeff

BioTex 05-26-2011 09:16 AM

Outstanding job! Now that you are a glass expert, you going to build a tub?:D

jcal73 05-26-2011 09:19 AM

Quote:

Originally Posted by BioTex (Post 11606657)
Outstanding job! Now that you are a glass expert, you going to build a tub?:D

No here in AL we use the creek once a week weather we need it or not!:laugh:

Jeff

243 05-26-2011 09:23 AM

Outstanding work Jeff :thumbsup:

This is the reason I hang out at JF :D

TBailey 05-26-2011 12:55 PM

Looks good.The only thing I would have done differently would be to gelcoat it.Fiberglass and fiberglass resin are not water proof.


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