Fibreglass Shroud Construction Tips 56K Warned

bryan_d · Jun 15, 2005

Hello all,

I have seen many posts on how to create your own shroud and there have been many suggestions that include the use of metal, acrylic, plastic and cardboard. I know this has been pointed out before I but I do believe fiberglass shrouds should be pushed more. I find them easy to build, with very few tools and materials, they can be changed easily, are easy to make look nice and are lighter for those who lug around their computers.

Here is a link to a site that has great info on constructing your own fiberglass shroud that I believe anyone can create:

http://web.njit.edu/~cas1383/proj/Glassing1/index.htm

When I made my shroud, I did not use any fancy dremel type tools or even use any wood. I used the Heatercore and some Styrofoam to make the shape of the shroud and just sealed those two using TIN FOIL!!

http://tinypic.com/2lozg0
http://tinypic.com/2lozkz
http://tinypic.com/5yyyi1
http://tinypic.com/4tpy5i
http://tinypic.com/4rq26o
http://tinypic.com/4tpydv
http://tinypic.com/4tpyc2

This is for more easier than buying a shroud made of steel that involves welding and for cheaper then buying on line too.

Hope that helps some,
Bryan D.

xcuriousgeorge · Jun 15, 2005

looks good man

you mean you used tin foil instead of tape to seal the shroud to the heater core? how did you make it stay on there?

bryan_d · Jun 16, 2005

xcuriousgeorge said:
looks good man

you mean you used tin foil instead of tape to seal the shroud to the heater core? how did you make it stay on there?

Thanks,

I still used foil tape to seal the cracks, I used tin foil to cover the heater core and styrofoam so the resin wouldn't stick to them.

Bryan D.

xcuriousgeorge · Jun 16, 2005

ohh okay, i knew i must have been misunderstanding that. lol

that's a good idea though

Flip-Mode · Jun 16, 2005

Well, you got me VERY interested now.
I have a few questions first:

1. Your tools section on your site is not done and I could us that info on fiberglass types.
2. How exactly did you make the shroud shape? I can't make it out from the pics.

bryan_d · Jun 17, 2005

The tool I used:
Credit Card- for smearing the fibreglass resin
Exacto knife- cutting excess cloth and also cutting the hole for the fan
Drill- cutting the mounting holes

Materials:
Resin Gelly
Hardner
Old Pantyhose and something to tie it with
120X120MM of foam
tin foil
Foil Tape

Here is a an illustration of how the shape was made:

Bryan D.

PS - Sorry if is confusing some

Flip-Mode · Jun 17, 2005

DAMN now it all clicks together!!!
I think I'm gonna go at it.
How thick was the foam? About 2cm?

bryan_d · Jun 17, 2005

I would make the foam at least 1" because that is the min to avoid the fan dead spot. The thicker the foam ther better.

If you want the shroud stronger you can add a layer of actual fiberglass and resin to the inside of the shroud. I never needed any more strength because I kind of liked the flexibility of my shroud.

Bryan D.

Flip-Mode · Jun 18, 2005

Great, thanks for the info. You can make a detailed guide and we can easly make it a sticky.

WillysNut · Jun 18, 2005

Bryan...this is an awesome idea..job well done! You should consider doing a more detailed writeup on this and submitting it for the front page. That would be the best way to "push" the idea as you say..

How much are the resin jelly and hardner?

Flip-Mode · Jun 18, 2005

According to his site if you look at a boating store you can find it <20$ a gallon for both together.

VballCoach · Jun 18, 2005

here's a link I used when I made my shrouds -
http://www.procooling.com/articles/html/how_to_make_a_composite_air_du.php

you can get the resin at Home Depot - 1 quart for ~ $10. It comes with hardener.
way more than you'll need.

noxqzs · Jun 18, 2005

instead of using tin foil and tape, why not just get metal duct tape, the one they use on ventilation. Its just like aluminum foil, but sticky.

VballCoach · Jun 18, 2005

noxqzs said:
instead of using tin foil and tape, why not just get metal duct tape, the one they use on ventilation. Its just like aluminum foil, but sticky.

yeah, that works well...I use the same stuff pretty much but it's called SpeedTape - rated up to 500mph - they use it on the outside of commercial aircraft. I use it 'cause my pc 'flies'...uh, I'm a dork...

voigts · Jun 18, 2005

This is really a good idea. Sounds very easy and you can make it any shape that you want. It would sure beat trying to cut the weird angles for a wood or acrylic shroud or trying to bend and solder metal.

bryan_d · Jun 18, 2005

noxqzs said:
instead of using tin foil and tape, why not just get metal duct tape, the one they use on ventilation. Its just like aluminum foil, but sticky.

Hmm... The aluminum foil is temp for just making sure the resin does not get on the HC, foil tape (metal duct tape) is used in the final sealing of the Shroud/HC though.

Thank you all for the positive comments and I will have a write up of the procedure shortly.

Bryan D.

Diggrr · Jun 18, 2005

Nice and easy. I saw them do the same thing (as the linked page) for speaker boxes and door panels on "Unique Whips" on the speed chanel.

I made mine the hard way I guess. Wood block molds covered in silicone sealant (non-stick surface). I vacuum bagged them with my wife's old food storage vacuum bagger.
I made mine from heavy surfboard glass cloth and used a Lay's potato chip bag for the release paper between the glass/resin and the vacuum bag.
5 identical dual-fan bonneville shrouds that way.

Fibreglass Shroud Construction Tips 56K Warned

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