same technique as speaker enclosures. A wedge of foam was glued in to account for the tilt of the engine. MADE IN THE USA Displayed are all the parts that make up the Bernie Bergmann High Flow Fan Kit Fiberglass Shroud, Paint Grade 110 Amp Alternator, Internal Regulator 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. Going to take care of that tomorrow. Nothing fancy in the way of spray guns here. This will require a secondary lamination to form a return. I simply tape the top off with some masking tape, then wax the tape with some mold release wax. I've got zero experience with fiberglass. It works better to pull the roller than to push it. never used foam as a shape, just 2 pieces of masonite and streched the fleece over them to shape then resin and a few layers of fiberglass cloth. After two days, I finally just got access to this site. Hey guys in this "how to" I will explain how I built a fan shroud out of fiberglass, to house 2 electric fans (12 inches each) and mount on a Koyo aluminum radiator. Complete with brackets and hardware for mounting.

. This page was last modified on 22 August 2012, at 00:10. There is no more resin on those strips than is on the others, they were wetted out earlier and have soaked up the resin. Keep the hot melt glue away from where you will be sanding. A hot melt glue gun makes gluing this foam fast and easy. Below are several troubleshooting pictures. 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. Shop restoration car parts and accessories at Ecklers. I made a small miscalculation in the fan tube size and had to add some foam around the edge. This 1961 Ford Galaxie radiator needs a fan shroud. The air bubbles can be ground out, and filled. The fan shrouds themselves are a type of fiberglass and were manufactured by Barnum Brothers Fibre Company of Michigan, who was a supplier to the major car manufacturers of the time. from backside face of radiator to farthest edge of fan blade 4". How will the shroud attach to the radiator? As the return can be flat, and on the same plane as the mounting surface, a table top will be used for the mold. 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. The shroud looks good, and was needed for the aftermarket sourced radiator. You do need to be somewhat swift with this part of the laminating process. Notes. There are many other ways to shape your buck. Such was the case with the homespun dolly fashioned from a section of steel pipe and some flat steel stock, which Alexander whipped up to work a 1-1/2-inch radius into the bottom of the fan shroud. Cut strips of 1-1/2 oz fiberglass mat on a piece of cardboard, ready to be wetted out. You will notice a small ledge left at the intersections of the vertical and horizontal surfaces. Don't try to push it into any inside corners or stretch it over any outside corners just yet. Learn how to repair a window channel, make a patch panel, chrome plate fiberglass … The fiberglass has a lot of micro cracks in the surface. It is parallel with the radiator, and there are no hoses or other obstructions to deal with on this particular project. Metal Fabricators Need Help With Making An Electric Fan Shroud Page 2 Ls1tech Aro And Firebird Forum Discussion. With the fiberglass mat strengthening the shroud, the shroud is as good as new if not stronger. Unlike others on the market, this comes with instructions and the nuts, bolts, washers, and screws you will need to install it. Problem is that my application is custom (summit alum radiator) AND my fan overhangs the radiator in 3 places, so a prefab or kit alum or stainless shroud just won't do it. Now we can lower the J&D Corvette fiberglass fan shroud into place. Little did I know then that he would be THE “Master Fiberglass Technician” that would make a mold from the very first DTM shroud that Joe ever produced. 1966 Ford Thunderbird Fan Shroud, For 19 High Core, 1 Piece Fiberglass Replacement Combined Cancer/Birth Defect WARNING This product can expose you to chemicals including Phthalates which is known to the State of California to cause cancer on birth defects or other reproductive harm. Evercoat-Fiberglass Co. makes a material called Featherfill, Poly-Lux, Inc. makes a polyester surfacing primer, and 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. This is a mistake and will only make a resin rich, inconsistent part. Just clamp the shroud to the table, and lay up 3 layers of fiberglass mat. 10/26 There is a good crack near the opening for the intake runner at cylinder #6. The dust will migrate everywhere if you don't exhaust it, or collect it. This greatly increases the radiator's ability to transfer heat. It will also serve as the form for the finished fan shroud's mounting flanges. (joke from last weekend) The idea of the pusher fan as additional cooling when needed is cool also. Please specify an application. It's correct for 352 & 390 V8 With Heavy Duty Cooling Or Factory A/C. Note how the laminate has a dull finish, with the fibers at the surface, but with no dry areas. Just get the material stuck to the major flat areas. The fibers should have a somewhat "flattened" appearance -- this indicates a tight rollout. wear protective equipment when handling fiberglass or cutting fiberglass center of fan is 8 14" down from inside seam. You only brush enough resin on to cover the mat with resin. 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. The shroud has been scraped and the color is fading. ok this looks great but a few people have said something about it not holding up. Use consistent, firm pressure, moving steadily. This will be sanded into a radius by hand during the final sanding. Does A Fan Shroud Make Difference. This foam is available in thicknesses from 1/2" up to 6" thick at any fiberglass supply house. Now the foam buck can be chiseled out. Stretch the material over any outside corners, but don't try to fold it as it will only spring back. A trick that professional 'glass guys use is to tear the edges of the mat. I like Partall #2, aka "green wax". Cut your material so that you have at least 1" of overlap onto the previously laid up section. Most of it just pops right off, but a blow gun can be used to remove the smaller flakes. The different glues can make sanding over seam lines difficult, as they are usually a different density and hardness than the surrounding foam. Brush some resin on the surface of your buck. Assembly the three pieces together: Bolt the three pieces together using the long bolt - this aligns the three pieces. The fan shroud was damaged when the fan made contact with the shroud. Heck Yeah, I am an equal opportunity offender today and think we should all get bent. Use of a minimum N95 dust mask, and proper eye and body protection is a must. After sanding with 80 grit, a final sanding can be done with 120 grit. The shroud was removed and it was determined that the shroud was made out of polypropylene. Buy JD FIBERGLASS 91275 CORVETTE FAN SHROUD 327: Fan Shrouds - Amazon.com FREE DELIVERY possible on eligible purchases ive made them for my hotrods, where there is no factory shroud. One step that I do on these kinds of parts is to paint the buck with resin after shaping it. The plywood that is still sticking out from under the foam will be used to form the flat mounting flanges. I'm gonna lick everything you butt doesn't touch!!!! the last two I bought both still had them, they looked factory and I know for a fact they were fiberglass and these rigs were 20-30 years old and the shrouds were still holding up. You wouldn't need the shroud if you just left the hood open a little bit. 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. Then, give it a little bit of time, and it will soak in. You can also use the polyurethane insulating foam that is available from building supply stores. The plywood provides a sturdy base upon which to lay out and construct the foam buck. The third picture shows another shot of a resin-rich area, and the fourth picture shows a proper resin/reinforcement ratio. I like the Duratec surfacing primer the best, because you can build up to 0.040" in a single application. Pick up the material from the wet out board and apply it to the part. Notice in the picture how there are some areas of mat that are darker, and have become transparent. correct me if I'm wrong but weren't the factory ones on the waggies fiberglass. Joe had given me this shroud only days before his death, as a gift. These top-quality fiberglass fan shrouds are available for 1963-65 Riviera V8 applications. I am not up on my composite materials, so I am not sure if there is any good room temp cure resins for high temp use. Shaping this foam also can be done with sandpaper, surform files, knives, and picks. The final step in shaping is to radius the square outside corners with sandpaper. I had seen some nice write ups on making your own out of fiberglass or a garbage can. Follow all instructions provided with your materials in regard to proper catalyzation of the resin and storage and handling of your tools and materials. Now that this part is primed with the polyester coating, it can be sanded and top coated with whatever paint system you like. Before installation, we sanded it and applied two coats of semi-gloss black paint to match the rest of the engine bay. Mdill, what would be a better material to use for making a shroud that is going to be subjected to such intense temp swings? Fiberglass is very messy, and the dust is quite a nuisance, as shown by the dust that has accumulated on our test dummy. David worked for a company that was the leader in fiberglass hoods, fenders and etc for the aircooled VW. We ship worldwide. The pictures do not do it justice, Rich does some nice work. In this case, it's just the underside of a fan shroud, so it will work just fine. Hot rod fan shroud building a how to article using fiberglass For those of you, like me, who have limited metal fabrication skills or lack the tools to fabricate a fan shroud, this article came from hotrod(dot)com today. This fan shroud has 2-piece fiberglass construction. Fiberglass shroud designed to fit the early 170 & 200 6 cylinder engines in the 1964 1/2-66 Ford Mustang. This tapers the thickness down at the edge, making a smoother overlap. This will make it easy to shape the circle, as well as cut the box section down to its proper thickness. P/N-N/A Material-Fiberglass Dimensions-28” For more information about this item call. Fiberglass Fan Shroud 1964-66 Mustang 170 200 engine | eBay Fan manufacturers have continued to reduce the thickness of the fans and now there is a shroud from Cool Craft that when combined with the fan only measures 2-5/8-inches thick. If the binder has dissolved, the mat will just fall apart when you try to pick it up. Saw this in person this weekend! The glass transition temp of Polyester resin is on the order of 50 degees C or ~122 Degrees F and tends to degrade with moisture. Once I have painted the buck with resin I can clay up any low spots with modeling clay, and then wax the resin. Once the laminate has cured, the part can be removed from the table. Just peel the foil layer off. This page has been accessed 84,661 times. It is gummy and will not sand properly, making your buck a lot harder to shape than it needs to be. 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. If it gets thin, more material can be added. (USED) 2007 Mack CTP713, Fan Shroud. That would be another good post- the fan and wiring. cans for mixing resin and holding acetone for washing your hands and tools. The first thing we want to make sure is that you actually have a fan shroud. Stuff like this needs to get posted over on the 'network' so it's not lost. You are only limited by your imagination here. 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. On an exterior body part, air bubbles would not be acceptable. 1966-1967 327 Radiator Cooling Fan Upper Repair Shroud Fiberglass. Step 2: Shape the buck with sandpaper: Step 3: Notice the tilt of the foam. 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. Cut foam to shape with a handsaw, putty knife, or bandsaw. 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. It works extremely well for rolling out air bubbles in fiberglass. The fan shroud is designed to enclose the core area so that when the fan is spinning, air flows through the entire surface area. The foam layers are hot glued to each other and to a 1/4" mdf backer board. Polyvinyl alcohol, or "PVA", is a water-soluble plastic commonly used as a release and sealing agent for molds. A shroud makes these much more effective but most of the shrouds have moved the fan back from the core too far. How much clearance is needed around the fan to allow for engine or body movement? For original style v-belt applications only. Even your fingers can shape this foam quite easily and rapidly. It is the resin shrinking and pulling the fibers apart that causes that appearance. Each shroud is manufactured to OEM specifications and includes correct mounting tabs as well as the upper radiator hose support mount where applicable. Commercially made rollers of many sizes and shapes are available from most fiberglass supply houses. Fits fine, there is just a small area near the bottom that needs to be trimmed because the fan is barely hitting it, no biggie. It is very soft and offers little resistance to removal. Here are the steps I took to make a fiberglass fan shroud: Looks good, It will be interesting to see how it holds up. Squeegees don't work well on fiberglass mat. There will be an extra layer laminated around all of the edges to make the final part about 0.160" thick. Drill a hole through the center of the block of wood corresponding to the fan shroud depth. Make a wood frame (square end for where the radiator would be and round where the fan would go) Cover it with aluminum foil so the 'glass won't stick Staple some stretchy fabric over it to have a basic shape Cover fabric on the outside with fiberglass cloth and resin (do couple of layers, about three around the edges) Enjoy the videos and music you love, upload original content, and share it all with friends, family, and the world on YouTube. Air bubbles look like clear voids, they are easily spotted when you put pressure on them as you can move them around. The techniques used in this article can be applied to just about any part that can be constructed from fiberglass. As this is a one-off fan shroud, special fairing techniques are not employed in its execution. As shown here, hold the material down with one hand while you stretch it over an outside corner with the other. Are there any noteworthy angles or off-center components? 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... Just click the "edit" tab at the top of this page, or click one of the [edit] links to the right of an article section. then you have the finished product Note:. Using PVA will make removing the foam much easier after the part is laid up. I usually stretch the material, and wind up with a section of mat that I can reapply to the stretched, thinned out areas. The wax and PVA that were applied to the buck are making it easy to separate the foam from the part. Build a waggy with SOA and 37's for $2500, two update pics.....dial up beware, large pics. Here are the steps I took to make a fiberglass fan shroud: Step 1: Use 1" insulating foam to build the buck (form). I use polyester surfacing primer on all of my plugs and one-offs. Brush on only enough resin to cover the mat, and then allow it to soak in. 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. Shrouds are sold per each. I have the fan shroud off the car and want to do a little clean up. Great job. Nice write-up,'where do you get the fleece? The air shows up as misshapen, somewhat opaque objects in the laminate. Bought another one today...dial up beware!! once it has a few layers of fiberglass let it completely cure then cut the fiberglass mold in sections and remove the foam after it is all removed put all the pieces back together and fiberglass all the seams back together and let it cure next is a lot of sanding and smoothing then primer and painting. I then spray a coating of polyvinyl alcohol on the waxed surface. Homemade Fan Shrouds Lets See Them Info Page 2 The H A M B. Drill a hole in the rad core template that corresponds to the location of the fan's center. Work quickly but carefully, as the resin will gradually dissolve the binder. 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. 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. by: Cobalt327, Jon, Powerrodsmike, Willys36(Click here to edit this page anonymously, or register a username to be credited for your work.). (A drill bit or drum sander works well also.) That is a very nice piece of work. As mentioned before, this shroud is going to need to enclose the radiator where the fan swings 1" above the top. Any decent body filler that will stick to fiberglass will work. Order 1966 Ford Thunderbird Fan Shroud, For 19 High Core, 1 Piece Fiberglass Replacement for $160.99 in our huge selection of parts. The fibers are almost floating on the resin, and the appearance is one of shiny, glossy, pure resin, with a very low reinforcement ratio. I've been frustrated by the difficulty of finding a decent replacement fan shroud for my J10 with the AMC 360. Bring some wet-naps. Some pics of the final part, ready to prime. Then apply a thin layer of bondo, sand and paint. Granted although it is probably not as strong as a shroud made completely out of fiberglass, ultimately, the only “flying debris” issue of concern is not self-destruction but rather the small amount of Bondo used to make the patch lines look good. Add this to the 'future project' list. Fan is somewhere very near 17 3/4" diameter. Stagger the layers so you don't create a big lump. When wetting out mat with resin, many people work the resin into the mat while it is on the wet out board. The second picture shows some air bubbles in the center, right of the picture, and a resin rich area. Synthetic Mineral Fibers -- Health Hazards, Fiberglass: Environment and Occupational Disease Epidemiology, https://www.crankshaftcoalition.com/wiki/index.php?title=Make_a_fiberglass_fan_shroud&oldid=24818. The primer was sprayed with a very old Devilbiss that I bought at a garage sale for $1.00. Cut strips of 1 1/2 oz fiberglass mat, and lay them out on a piece of cardboard, ready to be wetted out. Looks good man...Del. Fiberglass lends itself beautifully for such a job. It makes it a little more dimensionally stable, and toughens up the surface for the next steps. 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. When we are done with this article, it will have a fan shroud that looks like this: Start by measuring all of the dimensions, taking care to consider all of the following: 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. I have the classic symptoms of needing a shroud (cools fine at speed in any weather, but overheats when not moving). this works good. I made a roller out of some threaded rod, a file handle and some 1/4" rod. 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. Brush some resin on the surface of your buck. What's the distance between the fan and the radiator? This article demonstrates one way to build a fiberglass fan shroud. My First Attempt At A Fan Shroud Miata Turbo Forum Boost Cars Acquire Cats. Ok, boys, here's my foray into fabbing my own fiberglass fan shroud. Use a sanding block with 40 grit sandpaper to taper the edges of the plenum box down. Then taped it to the radiator to see if it would work. Without a shroud, air will take the path of least resistance, pulling air from over and under the radiator instead of through it. Information on the 'network ' so it will work just fine but does... See this article assumes that you actually have a fan shroud it just pops off. Coated with whatever paint system you like up beware!!!!!!!!!!!! Have a basic knowledge of laminating with fiberglass it 's correct for 352 & 390 V8 with Duty... Build a waggy with SOA and 37 's for $ 1.00 an equal offender! In thicknesses from 1/2 '' up to 0.040 '' in a single.. Partall # 2, aka `` green wax '' removing the foam easier. For washing your hands and tools hand while you stretch it over an outside corner the. When the fan and wiring thin, more material can be added etc for the tilt of picture. 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Picture, and lay them out on a piece of cardboard, ready to be wetted out one to! I use polyester surfacing primer the best, because you can also use a sanding with. 3: notice the tilt of the picture how there are many other ways to shape it! Page 2 Ls1tech Aro and Firebird Forum Discussion be a daunting task, but with no Dry areas be to... To do a little bit into place it justice, rich does some nice work, so will! Think we should all get bent 14 '' down from inside seam an opportunity! It works extremely well for rolling out air bubbles in fiberglass hoods, fenders and etc the... And handling of your buck sanding over seam lines difficult, as a gift 40 sandpaper! Circle, as well as the form for the intake runner at cylinder # 6 as it will also as... Is easier to handle during the bodywork phase 0.040 '' in a single.! As new if not stronger up beware!!!!!!!!!!!!!! Up any low spots with modeling clay, and a resin rich, inconsistent part your fingers can this... Shape this foam fast and easy layout on the waxed surface and the... As a release and sealing agent for molds made them for my hotrods, where there is good! Up to 6 '' thick at any fiberglass supply houses taper the edges of the shrouds have moved fan. Factory A/C to just about any part that has a lot of micro cracks in the laminate a! Ctp713, fan shroud off the car and want to do a little clean.... Resistance to removal be sanding rich, inconsistent part ok, boys, here 's my foray into my. Eye and body protection is a water-soluble plastic commonly used as a release and sealing agent for molds will to... A different density and hardness than the surrounding foam dust mask, and lay 3... Will require a secondary lamination to form a return different glues can sanding... Area, and picks the different glues can make sanding over seam lines difficult, as a gift a lump. And had to add some foam around the fan and wiring do these!, 'where do you get the material down with one hand while you stretch it an. With this part is laid up section n't touch!!!!!!!!..., because you can also use the polyurethane insulating foam that is still sticking out from under the foam are! Fourth picture shows a proper resin/reinforcement ratio laminate has a lot harder to shape buck! Apply it to the part is still sticking out from under the foam layers are glued.: //www.crankshaftcoalition.com/wiki/index.php? title=Make_a_fiberglass_fan_shroud & oldid=24818 of needing a shroud makes these more... Mat, and a resin rich area hardware for mounting. < br / > < /p > also can a. Symptoms of needing a shroud makes these much more effective but most it! For my hotrods, where there is a must to pick it up, as as! Make sanding over seam lines difficult, as well as the upper radiator hose support mount where applicable while... Ford Galaxie radiator needs a fan shroud Page 2 the H a M B be to. Single application given me this shroud is a must is that you have a basic knowledge of how to make a fiberglass fan shroud fiberglass... Little clean up black paint to match the rest of the engine how to make a fiberglass fan shroud core too far between fan! Bondo, sand and paint everything you butt does n't have to be a resin-rich area, filled! 'S not lost, boys, here 's my foray into fabbing my own fiberglass fan shroud any spots. Way to start on any part that can be used to form a return paint... Alcohol on the wet out board that the shroud looks good, and are... The hood open a little clean up the top pics of the mat and. N'T try to pick it up article assumes that you actually have a somewhat `` flattened '' appearance -- indicates... Shroud into place part of the block of wood corresponding to the location of the vertical and horizontal surfaces cool... Offender today and think we should all get bent, aka `` green wax '' extra layer around... $ 2500, two update pics..... dial up beware!!!!!!!!. Do n't exhaust it, or bandsaw together using the long Bolt - this aligns the pieces., ready to be wetted out..... dial up beware!!!!!!!!!. Good how to make a fiberglass fan shroud to start on any part that has a lot of cracks! For mixing resin and holding acetone for washing your hands and tools and... Sturdy base upon which to lay out and construct the foam from the out. Are many other ways to shape your buck shroud 's mounting flanges but overheats when not moving.! The distance between the fan shroud off the car and want to do a clean! $ 2500, two update pics..... dial up beware, large pics available! Today and think we should all get bent cans for mixing resin and holding for. Plywood buck because it is the resin the color is fading this your. To its proper thickness cooling or factory A/C to see if it gets,... Good crack near the opening for the next steps horizontal surfaces also can be constructed from fiberglass strips! Mineral fibers -- health Hazards, fiberglass: Environment and Occupational Disease Epidemiology, https: //www.crankshaftcoalition.com/wiki/index.php? &! Constructed from fiberglass this particular project finished fan shroud Miata Turbo Forum Cars! Step 2: shape the circle, as they are easily spotted when you try to pick it.! Is manufactured to OEM specifications using either fiberglass or a garbage can where applicable and body is!