Building A fan Shroud CAUTION LONG AND PIC HEAVY!! - JeepForum.com
Search  
Sign Up   Today's Posts
User: Pass: Remember?
Advertise Here
Jeep Home Jeep Forum Jeep Classifieds Jeep Registry JeepSpace Jeep Reviews Jeep Gallery Jeep Clubs Jeep Groups Jeep Videos Jeep Events Jeep Articles
Go Back JeepForum.com > Models > Jeep CJ Forum > Building A fan Shroud CAUTION LONG AND PIC HEAVY!!

ECGS Black Friday Sale!!6th Annual, Beat Your Wife to the Credit Card Sale!50 in light bar /A pillar mount less than 500 at JeepHut.c

Reply
Unread 05-26-2011, 08:16 AM   #1
jcal73
Web Wheeler
 
jcal73's Avatar
1979 CJ5 
 
Join Date: Nov 2007
Location: Alabama Roll Tide
Posts: 1,076
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.



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!





Jeff

jcal73 is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 08:16 AM   #2
jcal73
Web Wheeler
 
jcal73's Avatar
1979 CJ5 
 
Join Date: Nov 2007
Location: Alabama Roll Tide
Posts: 1,076
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!

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.



A few of the incorrect shroud build









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.









The template is longer at the top than bottom to make up of for the tilt of the engine.


More to follow.


Jeff
jcal73 is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 08:16 AM   #3
jcal73
Web Wheeler
 
jcal73's Avatar
1979 CJ5 
 
Join Date: Nov 2007
Location: Alabama Roll Tide
Posts: 1,076
Stretched Fleece and stapled.




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.



I then mixed some resin and soaked the fleece, let it dry and mixed and applied a very heavy coat.








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


Jeff
jcal73 is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 09:07 AM   #4
jcal73
Web Wheeler
 
jcal73's Avatar
1979 CJ5 
 
Join Date: Nov 2007
Location: Alabama Roll Tide
Posts: 1,076
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.


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.




Next I cut out the round part of the template with the dremel.




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





I had to smooth out some places for clearance.


Now to paint finishing.
I primed the shroud.


Sanded and glazed and sanded and sanded and sanded! You get the idea!


I sprayed it semi-gloss black.




Then I scratched it all up installing it!


Next onto brackets and installation.



Jeff
jcal73 is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 09:15 AM   #5
jcal73
Web Wheeler
 
jcal73's Avatar
1979 CJ5 
 
Join Date: Nov 2007
Location: Alabama Roll Tide
Posts: 1,076
I made small brackets to hold the shroud in place out of some small bar flat that I had lying around.





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







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!




Jeff
jcal73 is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 09:24 AM   #6
rixcj
Web Wheeler
 
rixcj's Avatar
1979 CJ5 
 
Join Date: Jun 2007
Location: RI
Posts: 1,709
You did a great job! Congrats!

Thanks for posting this.

Rich
__________________
'79 CJ5, AMC 360, t-18/d20 twin stick, dana 30/amc20(Mosers), Edelbrock Performer intake, Holley 600, ps/pb, DUI HEI, 'glass tub/1pc. tilt nose, 33x12.50 BFG AT's.

There's a fine line between "hobby" and "mental illness".
rixcj is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 09:37 AM   #7
CrawlingForward
Rookies Happen.
 
CrawlingForward's Avatar
1995 YJ Wrangler 
 
Join Date: Nov 2008
Location: Brazoria, Texas
Posts: 2,325
Wow! Great write-up and a nice product!
__________________
My Other Jeep Is A Jeep - Crawlingforward's Jeep-Related Adventures

95 YJ, Rio Grande - The Wannabe Sleeper Wheeler
2010 JKU, Islander Edition - The Burly Stock Overlander

- North Shore Jeep Club -
Build/Wheel/Break/Educate/Upgrade/Repeat
CrawlingForward is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 10:01 AM   #8
mikeumkc
Registered User
2009 JK Wrangler 
 
Join Date: Mar 2003
Location: Overland Park, KS
Posts: 215
I absolutely LOVE your paint studio. hahaha. Awesome.
__________________
2009 JKU Rubicon. stock now.... I'm working on it.
mikeumkc is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 10:05 AM   #9
jcal73
Web Wheeler
 
jcal73's Avatar
1979 CJ5 
 
Join Date: Nov 2007
Location: Alabama Roll Tide
Posts: 1,076
Quote:
Originally Posted by mikeumkc View Post
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
jcal73 is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 10:12 AM   #10
drerict
Registered User
1983 CJ7 
 
Join Date: Jul 2007
Location: Alamosa, CO
Posts: 121
Looks good, I may be copy your idea for mine.
__________________
Firefighters Jeep Club
http://groups.jeepforum.com/Firefighters_Jeep_Club
drerict is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 10:14 AM   #11
jcal73
Web Wheeler
 
jcal73's Avatar
1979 CJ5 
 
Join Date: Nov 2007
Location: Alabama Roll Tide
Posts: 1,076
Quote:
Originally Posted by drerict View Post
Looks good, I may be copy your idea for mine.
Go ahead! I copied others to build it!


Jeff
jcal73 is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 10:16 AM   #12
BioTex
Registered User
2006 TJ Wrangler 
 
Join Date: May 2008
Location: Alpine, Tx.
Posts: 3,173
Outstanding job! Now that you are a glass expert, you going to build a tub?
__________________
'85 CJ7, BDS 4" lift, 1" Body lift, 33x12.5, Shrockworks Sliders, 304 V8 with RV cam., T-176, D300, Dana 30, AMC 20.
1986 CJ10-A SD-33 Diesel/727/np208
1971 800B with 345/T-19
06' TJ Rubicon, 4" R.C. springs, BFG/AT 35s M.C. 6" fenders, rockers and surrounds, Currie front & rear adj. tracbars, tattons DC rear shaft, adj. upper - lower CA's. Bilstein 5100's
YJ Buggy Build Current project. Stroker/FI ?
1990 MJ Comanche 4.0L AX15/np231
BioTex is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 10:19 AM   #13
jcal73
Web Wheeler
 
jcal73's Avatar
1979 CJ5 
 
Join Date: Nov 2007
Location: Alabama Roll Tide
Posts: 1,076
Quote:
Originally Posted by BioTex View Post
Outstanding job! Now that you are a glass expert, you going to build a tub?
No here in AL we use the creek once a week weather we need it or not!

Jeff
jcal73 is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 10:23 AM   #14
243
Registered User
1983 CJ7 
 
Join Date: Sep 2002
Posts: 3,274
Outstanding work Jeff

This is the reason I hang out at JF
__________________
You can't sit at the big boy table if you are gonna whine like a girl...M
243 is offline   Reply With Quote Quick reply to this message
Unread 05-26-2011, 01:55 PM   #15
TBailey
Registered User
1983 CJ7 
 
Join Date: Dec 2009
Location: Pensacola,FL
Posts: 305
Looks good.The only thing I would have done differently would be to gelcoat it.Fiberglass and fiberglass resin are not water proof.
TBailey is offline   Reply With Quote Quick reply to this message
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the JeepForum.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.
Note: All free e-mails have been banned due to mis-use. (Yahoo, Gmail, Hotmail, etc.)
Don't have a non-free e-mail address? Click here for a solution: Manual Account Creation
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.


Thread Tools


Suggested Threads





Jeep, Wrangler, Cherokee, Grand Cherokee, and other models are copyrighted and trademarked to Jeep/Chrysler Corporation. JeepForum.com is not in any way associated with Jeep or the Chrysler Corp.