Fiberglass Shroud for Bonney *56K WARN*

Hello all,

This is a simple collection of pictures and comments on my fiberglass shroud for the famous 1979 Bonneville Heatcore w/AC. It starts from the day I bought it, to the day it was all strapped together.

I must warn all those who are thinking that this will be a Weapon Shroud killer, it is not. It might perform just as well, but will never look as good... with my patience anyway This will be explained later.

Here are some of the materials that I had gathered, there are more you will be introduced to later on but these are what I thought I would be using before the project.

http://i5.photobucket.com/albums/y196/bryan_d/000_0719.jpg

I then proceeded to cut, with a razor, two layers of foam, equaling 2", the exact same dimensions as the HC and glued them together.

http://i5.photobucket.com/albums/y196/bryan_d/000_0724.jpg

I then used a razor blade to shape the foam.

http://i5.photobucket.com/albums/y196/bryan_d/000_0744.jpg

After I got the shape that I wanted, I then proceeded to sealing the foam core with duct tape and tin foil! This would prevent the foam from being eaten away by the fibreglass resin.

http://i5.photobucket.com/albums/y196/bryan_d/000_0751.jpg

I took some old T-shirt and wrapped the HC/Foam and made sure the cloth was pressed against the foam as best as possible.

http://i5.photobucket.com/albums/y196/bryan_d/000_0753.jpg

I then busted out the fibreglass resin. Mix according to the lable!

http://i5.photobucket.com/albums/y196/bryan_d/000_0754.jpg

All mixed up and I just poured that stuff right over the cloth.

http://i5.photobucket.com/albums/y196/bryan_d/000_0755.jpg

I then used an old credit card to apply it all over the cloth covering the foam.

http://i5.photobucket.com/albums/y196/bryan_d/000_0756.jpg

It then dried into this.

http://i5.photobucket.com/albums/y196/bryan_d/000_0758.jpg

Then for strength I busted out this stuff and again mix according to the lable. This stuff was harder to apply than the first because of the built in fibreglass strands. No here is where you might want to differ in that buy using this stuff you are guranteed some UGLINESS. Unless you sand and fill like a mofo.

If you do not want to do either, you can simple apply more of the normal Resin until you get a thickness that you want, meaning when its hard and it feels hard enough for you liking. This resin will be easier to sand and make your shroud look nicer.

I do not care for looks for my comp so here I go with the nasty.
http://i5.photobucket.com/albums/y196/bryan_d/000_0738.jpg

This is how it looks when applied

http://i5.photobucket.com/albums/y196/bryan_d/000_0759.jpg

The fibreglass resin all hard and looking nasty as heck!

http://i5.photobucket.com/albums/y196/bryan_d/000_0763.jpg

I simply pulled off the hardened shroud and cut off all the excess cloth and fibreglass with some normal scissors. I got some low grit sand paper out and went to it.

http://i5.photobucket.com/albums/y196/bryan_d/000_0792.jpg

After it was smooth enough for my liking I then proceed to make out my cuts. Again, here you can acutally choosed to fill in the gaps with more resin to make everything looking flat and proffessional if you want.

http://i5.photobucket.com/albums/y196/bryan_d/000_0795.jpg

I then busted out the razor blade and drill.

http://i5.photobucket.com/albums/y196/bryan_d/000_0797.jpg

I didn't want it looking too ugly, so what the heck.

http://i5.photobucket.com/albums/y196/bryan_d/000_0799.jpg
http://i5.photobucket.com/albums/y196/bryan_d/000_0800.jpg
http://i5.photobucket.com/albums/y196/bryan_d/000_0801.jpg
http://i5.photobucket.com/albums/y196/bryan_d/000_0802.jpg

I cut some tinfoil tape... aluminum duct tape... whatever.

http://i5.photobucket.com/albums/y196/bryan_d/000_0806.jpg

And slapped them on to seal and hold the shroud onto the HC!And VOILA!

http://i5.photobucket.com/albums/y196/bryan_d/000_0808.jpg

Looks awesome. Its rather... huge though Could you put the fans on the inside of the shroud to save space? It shouldnt effect performance too terribly much.

thats the uglies looking shoud ever , nice work though. I applaud your effort, id never have the time/patience to try it but wouldl like tp play with plexiglass some time.

Very nice job! i was gonna do a legit shroud, but then i was like DONT HAVE TIME! and got a razor knife and a MSI k8n neo box, and built a cardboard beauty. i wish i had the time to do a nice legit shroud. it looks great. good job.

And its probably that tall to kill all deadspots in the fans.

Nice job, pity you left it unfinished after all the work you put in.

Nice shroud, not ugliest though

Mine is some old 4L margarine tub cut up, then 4 sides individually cut up and pushed onto each side of the HC, then fans pushed in with ductape using to space them, then the whole ordeal is smothered in more duct tape in order to provide a friendly seal.

I certainly don't think its ugly at all. It could look 'better' if it were finished with some paint or such, but that is a work of art. Very nice job. And the size of it is ideal, def not too big. Didn't the mathematics suggest a shroud 5x the thickness of the fan itself for best performace? While 5x might be a lot of space occupied inside your case, the closer you get the better it will work.

Nice work d.

citronym said:

I certainly don't think its ugly at all. It could look 'better' if it were finished with some paint or such, but that is a work of art. Very nice job. And the size of it is ideal, def not too big. Didn't the mathematics suggest a shroud 5x the thickness of the fan itself for best performace? While 5x might be a lot of space occupied inside your case, the closer you get the better it will work.

Nice work d.

Click to expand...

No way its 5X, think about it. The fan is 25mm think so 25mm*5=125mm=12.5cm.
And what if you have 38mm fans....wow.
Anyhow as far as I know its so posed to clear 1.5'.

citronym said:

I certainly don't think its ugly at all. It could look 'better' if it were finished with some paint or such, but that is a work of art. Very nice job. And the size of it is ideal, def not too big. Didn't the mathematics suggest a shroud 5x the thickness of the fan itself for best performace? While 5x might be a lot of space occupied inside your case, the closer you get the better it will work.

Nice work d.

Click to expand...

Yeah, that '77bonne looks fully operational. That's the ruff finish that you get on boats with fiberglass in the corners, tight spaces etc... But they come back and sand it down........If you sand that down until it's evenly smooth, I don't see why you wouldn't be mass-producing those.

Way to think outside the box on that shroud! The best time to have sanded it would've been while it was over the mold. That has to be one of the strongest shrouds out there.

Flip-Mode said:

No way its 5X, think about it. The fan is 25mm think so 25mm*5=125mm=12.5cm.
And what if you have 38mm fans....wow.
Anyhow as far as I know its so posed to clear 1.5'.

Click to expand...

I can't find the post to back up that claim now, but someone who seemed to understand the math and physics involved said that at 5x the thickness of the fan, the dead spot is gone and there is even pressure accross the whole surface, and anything greater than 5x begins to negate the principal involved with using the shroud.

That said, 5x38mm IS just rediculous, especially considering most of us use internal rads. My point was simply that the bigger you have it, the better, but at a certain point you will certainly hit the "too much" mark.

If anyone knows what article I've been referring to and has it handy I'd like to save that one.

citronym said:

I can't find the post to back up that claim now, but someone who seemed to understand the math and physics involved said that at 5x the thickness of the fan, the dead spot is gone and there is even pressure accross the whole surface, and anything greater than 5x begins to negate the principal involved with using the shroud.

That said, 5x38mm IS just rediculous, especially considering most of us use internal rads. My point was simply that the bigger you have it, the better, but at a certain point you will certainly hit the "too much" mark.

If anyone knows what article I've been referring to and has it handy I'd like to save that one.

Click to expand...

Actualy I heard it was something like 7-8.

Most people are happy with a couple inches

That is freakin sweet. Now do one for the other side.

ls7corvete said:

Actualy I heard it was something like 7-8.

Most people are happy with a couple inches

Click to expand...

cant remember..... but 2x-3x the HUB diameter (center thing that is causing the dead spot) comes to mind

Thanks all,

Well my first shrouds worked pretty fine I believe. They were only about an inch thick. I noticed that the dust collecting on the RAD was fairly even so that was a sign that air was passing through out the whole RAD. Thought that was a push/pull config while this new one will be strictly pull.

Here is my first Fibreglass shroud:
http://tinypic.com/4tpy5i
http://tinypic.com/4rq26o
http://tinypic.com/4tpydv
http://tinypic.com/4tpyc2

This new shroud which is even deeper, should perform better than my first. The HC is much better also; being an all copper construction and all. The last one was brass and had smaller surface area.

Like I said, I had no means of making it look nice because my case does not even have a window. I just put some paint on the shroud because I noticed there was still some dust on it and I just made the poor attempt of "sealing" the dust in It really was not much work really. Just sitting around waiting for the resin to cure was the most difficult part!

And for that person who said they would rather work with plexiglass than fiberglass. I thikn the plexiglass would be much harder. With the fiberglass I had more room for error because I knew everything could be filled and sanded as I wished. If you cut too short with plexiglass... then you have to start over. Plexiglass is also heavier. It would prbably look better but I not doing this for looks.

Bryan D.

Great write up. I'm thinking about giving this a try sometime this summer.

You need to pull that cloth tighter........ and bondo. Take pride in your work, man.

BTW, thats much better than the other shroud.

ls7corvete said:

Most people are happy with a couple inches

Click to expand...

Most women would disagree with that

Jas said:

Most women would disagree with that

Click to expand...

Eh, well I have the too big problem so I wouldnt know.

Wow! You guys know girls!?!?! I heard rumors that their hair smell nice!

But back to the subject of geekdum that is OCforums, the cloth I really half arsed because I wanted this simple and quick... and also I could not find any pantyhose because that stuff works the best. It really pulls on tight.

I do take pride in my work... with better temps that is I just do not see the need to make it look awesome because I keep the comp in a little cabinet under my huge desk and my case has no window. I take pride in that fact that is makes a perfect seal and it could probably hold my full weight on it, but other than that... its still going to be "all go and no show".

Thanks for suggestions and compliments all,
Bryan D.