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Subject e-Fan Shroud and slam panel fabrication (pic heavy)
     
Posted by andygp on December 06, 2010 at 7:32 AM
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Message Well you may remember that I had upgraded my rad, and was in the process of making my own slam panel to go across the top of the front of the engine bay and join with the engine skins.

Looked like this once:
Photobucket

Photobucket

As many pointed out - this was pretty pathetic for cooling and would probably be an epic fail resulting in hot spots on the rad and general engine overheating.

e-fan on rad with 'air-guide' - shall we call it!
New Rad & Fan Attached

It was always my intention to make a fan shroud, but needed to complete the build to a stage to where I knew how much room I had to play with, and how I wanted the whole thing to fit together and be usable, and servicable!

I made the shroud buck out of some scrap wood and some posterboard layed on top of the actual rad:
Fan Cowling

Popped in some recessed corners for the plumbing:
Fan Cowling

Fan Cowling

I had by that time gotten the slam panel to a design that I could work with moving forward, and now needed to join everything up as envisaged...

This is the slam panel:
Photobucket

And here is the shroud mounted on the rad, with the e-fan in place and you can see the cutaway for the slam panel;
Fan Cowling

You can see where this is going I hope:
Slam Panel:
Fan Cowling

Et Voila!
Fan Cowling

Fan Cowling

Next stage was to add the shiny cover back into the mix:
Here it is screwed to the slampanel for the forming of the correct shape:
Photobucket

I then riveted it on to the shroud leaving about half an inch clearance for airflow into the top of the rad/cover:

These two ends will be finished/rounded out real soon:
Photobucket

Now I just need to fix it all together so that it is easily removable for servicing/cleaning - I decided to use the same quick release bolts that I have in my intake manifolds:
Fan Shroud - November

Fan Shroud - November

Fan Shroud - November

There will be a line of rubber seal/draught excluder along this line when done:
Photobucket

Done - now to carbonate the shroud/cover:

Photobucket

Followed by 2 flood coats of my favorite surfboard resin:
Photobucket

Photobucket

Photobucket

Waiting for this to cure, then wet sand with 1500 and buff/polish and trim. Then its going back on the car.

The slam panel is bolted to the headlamp frames and retains the floating radiator that has locating pins in the lower chassis: The slam panel is connected to and supports the fan shroud which is screwed to the bottom of the rad and has sealer strip around the perimiters: I have left a 1" open section at the base to release any water buildup.

To remove the rad its going to be remove: 2 screws to remove the FPR and the belt cover: 2 x quick release skewers, 4 x slam panel dzus fasteners, and 2 x screws in the base of the rad - and the two hoses - I'm happy with that!

Will post when I have fitted pics.

Any questions, queries and comments always appreciated.

     
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