Make a fiberglass fan shroud
(→Shaping and gluing the foam) |
(→Forming the circular part of the shroud) |
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===Forming the circular part of the shroud=== | ===Forming the circular part of the shroud=== | ||
It's often the case that part of the shroud will need to be perfectly round. If so, set up the buck with a bolt or nail in the center, and fix it to your drill or mill table so that it can be spun by hand against an end mill. ( A drill bit or drum sander works well also.) This will make it easy to shape the circle, as well as cut the box section down to its proper thickness. There are many other ways to shape your buck. You are only limited by your imagination here. | It's often the case that part of the shroud will need to be perfectly round. If so, set up the buck with a bolt or nail in the center, and fix it to your drill or mill table so that it can be spun by hand against an end mill. ( A drill bit or drum sander works well also.) This will make it easy to shape the circle, as well as cut the box section down to its proper thickness. There are many other ways to shape your buck. You are only limited by your imagination here. | ||
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You will notice a small ledge left at the intersections of the vertical and horizontal surfaces. This will be sanded into a radius by hand during the final sanding. | You will notice a small ledge left at the intersections of the vertical and horizontal surfaces. This will be sanded into a radius by hand during the final sanding. | ||
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The plywood that is still sticking out from under the foam will be used to form the flat mounting flanges. | The plywood that is still sticking out from under the foam will be used to form the flat mounting flanges. | ||
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Use a sanding block with 40 grit sandpaper to taper the edges of the plenum box down. | Use a sanding block with 40 grit sandpaper to taper the edges of the plenum box down. | ||
| − | [[Image:14edge detail.JPG| | + | {| |
| + | |-valign="top" | ||
| + | |[[Image:10fast way to make a perfect circle.JPG|thumb|center|A bolt centered in the buck allows it to be spun against an end mill to shape the circle.]] | ||
| + | |[[Image:11more shaping.JPG|thumb|center|The buck is spun by hand to form the circular portion of the shroud shape.]] | ||
| + | |[[Image:13roughed out some more.JPG|thumb|center]] | ||
| + | |[[Image:14edge detail.JPG|thumb|center]] | ||
| + | |} | ||
| − | I made a small miscalculation in the fan tube size and had to add some foam around the edge. The final step in shaping is to radius the square outside corners with sandpaper | + | I made a small miscalculation in the fan tube size and had to add some foam around the edge. The final step in shaping is to radius the square outside corners with sandpaper. |
| − | [[Image:15final shape.JPG|center| | + | {| |
| − | + | |-valign="top" | |
| − | + | |[[Image:15final shape.JPG|thumb|center|The bottom of the shroud.]] | |
| − | + | |[[Image:16more final shape.JPG|thumb|center|The right side of the shroud.]] | |
| − | [[Image:16more final shape.JPG|center| | + | |[[Image:18even still more final shape.JPG|thumb|center|The left side of the shroud.]] |
| − | + | |} | |
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| − | [[Image:18even still more final shape.JPG|center| | + | |
One step that I do on these kinds of parts is to paint the buck with resin after shaping it. It makes it a little more dimensionally stable, and toughens up the surface for the next steps. | One step that I do on these kinds of parts is to paint the buck with resin after shaping it. It makes it a little more dimensionally stable, and toughens up the surface for the next steps. | ||
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Once I have painted the buck with resin I can clay up any low spots with modeling clay, and then wax the resin. I then spray a coating of polyvinyl alchohol on the waxed surface. Polyvinyl alcohol, or "PVA", is a water-soluble plastic commonly used as a release and sealing agent for molds. Using PVA will make removing the foam much easier after the part is laid up. | Once I have painted the buck with resin I can clay up any low spots with modeling clay, and then wax the resin. I then spray a coating of polyvinyl alchohol on the waxed surface. Polyvinyl alcohol, or "PVA", is a water-soluble plastic commonly used as a release and sealing agent for molds. Using PVA will make removing the foam much easier after the part is laid up. | ||
| − | [[Image:20wax and PVA.JPG| | + | {| |
| + | |-valign="top" | ||
| + | |[[Image:19paint with resin.JPG|thumb|center|When shaping is complete, the buck is painted with resin.]] | ||
| + | |[[Image:20wax and PVA.JPG|thumb|center]] | ||
| + | |} | ||
===Laminating the part=== | ===Laminating the part=== | ||
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