Make a fiberglass fan shroud
(→Shaping and gluing the foam) |
(→Forming the circular part of the shroud) |
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[[Image:10fast way to make a perfect circle.JPG|center|600px|A bolt centered in the buck allows it to be spun against an end mill to shape the circle.]] | [[Image:10fast way to make a perfect circle.JPG|center|600px|A bolt centered in the buck allows it to be spun against an end mill to shape the circle.]] | ||
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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. | ||
[[Image:11more shaping.JPG|center|600px|The buck is spun by hand to form the circular portion of the shroud shape.]] | [[Image:11more shaping.JPG|center|600px|The buck is spun by hand to form the circular portion of the shroud shape.]] | ||
| + | The plywood that is still sticking out from under the foam will be used to form the flat mounting flanges. | ||
[[Image:13roughed out some more.JPG|center|600px]] | [[Image:13roughed out some more.JPG|center|600px]] | ||
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| + | Use a sanding block with 40 grit sandpaper to taper the edges of the plenum box down. | ||
[[Image:14edge detail.JPG|center|600px]] | [[Image:14edge detail.JPG|center|600px]] | ||
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| + | 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. You are looking at the bottom of the shroud in this picture. | ||
[[Image:15final shape.JPG|center|600px]] | [[Image:15final shape.JPG|center|600px]] | ||
| − | [[Image:16more final shape.JPG|center|600px]] | + | Looking from the right side. |
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| + | [[Image:16more final shape.JPG|center|600px]] | ||
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| + | Looking from the left side. | ||
[[Image:18even still more final shape.JPG|center|600px]] | [[Image:18even still more final shape.JPG|center|600px]] | ||
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[[Image:19paint with resin.JPG|thumb|center|600px|When shaping is complete, the buck is painted with resin.]] | [[Image:19paint with resin.JPG|thumb|center|600px|When shaping is complete, the buck is painted with resin.]] | ||
| − | Once I have painted the buck with resin I can clay up any low spots, 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 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|center|600px]] | [[Image:20wax and PVA.JPG|center|600px]] | ||
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===Laminating the part=== | ===Laminating the part=== | ||
Cut strips of 1 1/2 oz fiberglass mat on a peice of cardboard, ready to be wetted out. 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. There will be an extra layer laminated around all of the edges to make the final part about 0.160" thick. | Cut strips of 1 1/2 oz fiberglass mat on a peice of cardboard, ready to be wetted out. 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. There will be an extra layer laminated around all of the edges to make the final part about 0.160" thick. | ||
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