Umair Gaines
Electric fan shrouds are great for preventing your car from overheating in hot temperatures. They can be made with basic tools and simple metalwork skills. In this article, we will walk you through the process of building your own electric fan shroud, including the materials and tools you will need, as well as some tips and tricks to make the process easier. We will also discuss the benefits and limitations of using a fan shroud, and provide some examples of common fan shroud setups used in the automotive community.
| Characteristics | Values |
|---|---|
| Materials | Aluminum, Epoxy, Glass |
| Tools | Rivet Gun, Propane Torch, Simple Hand Tools |
| Techniques | Bending, Cutting, Sealing |
| Considerations | Gauge/Thickness, Fan Configuration, Efficiency, Aerodynamic Load |
| Additional Features | Flapper Doors, Wiring, Relays |
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What You'll Learn
- Sourcing materials: Aluminium angle can be sourced for cheap or free from scrap places, Craigslist, or trash
- Design: Fan shrouds can be made from old street signs or baking sheets
- Assembly: Most electric fans come as an assembly with the shroud
- Installation: Shrouds can be attached with rivets and sheet metal screws
- Function: Electric fans are more efficient with shrouds, but shrouds can restrict airflow at high speeds
Sourcing materials: Aluminium angle can be sourced for cheap or free from scrap places, Craigslist, or trash
Aluminium angle is a product with two legs that form a 90-degree angle. It is used in structural applications and general fabrication. You can purchase it online or at a metal supermarket, cut to your exact specifications.
If you're looking to source aluminium angle on a budget, scrap places and scrapyards are a great option, provided you can find one open to the public that has what you need. You can also try Craigslist or your local equivalent. Another option is to find a bulk sales facility. If you don't know of any, you can ask any machine shop, and they'll be able to tell you where they buy their bulk stock from.
Online Metals is a good online source for standard and custom-cut aluminium angle lengths. You can also try Metal Supermarkets, which has over 130 locations serving the United States and Canada.
If you need the aluminium angle right away, you may have to opt for a home improvement store like Home Depot, Lowes, or Hughs Lumber, though these options tend to be more expensive.
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Design: Fan shrouds can be made from old street signs or baking sheets
Fan shrouds can be made from a variety of materials, including old street signs or baking sheets. If you're using an old street sign, make sure it's large enough to fit your fan and cut out a hole in the centre for the fan to fit through. You can use rivets and screws to attach the shroud to your fan.
One user opted to use an aluminium sheet pan to make their fan shroud. They cut the pan for the radiator hoses and made a foam gasket to go around the edge, sealing off the outer parts of the radiator. They also cut out a hole in the centre for the fan.
Another user suggested using large restaurant-grade aluminium baking sheets to make a fan shroud. This material is sturdy and can be cut and shaped to fit your fan.
If you're looking for a more lightweight option, you can consider using fiberglass. It is strong, withstands high temperatures, and can be finished with automotive primers, fillers, sealers, and paints. The process is simple and only requires a few tools and inexpensive materials.
When designing your fan shroud, it's important to consider the gap between the shroud and the radiator. A small gap can increase airflow and improve the efficiency of your fan. However, if the gap is too large, it can create a vacuum and affect the performance of your fan.
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Assembly: Most electric fans come as an assembly with the shroud
Assembly
Most electric fans come as an assembly with the shroud. However, if you are building your own, there are a few things to keep in mind. Firstly, electric fans are preferred to mechanical belt-driven fans because they are easier to mount with a plastic or metal shroud. Electric fans are also more efficient as they are controlled by a temperature sensor and only engage when needed.
When assembling an electric fan with a shroud, it is important to ensure that the fan blades are recessed 50% into the shroud for optimum cooling. This can be achieved by using fan spacers or shims to get the correct fan placement within the shroud. The shroud should be placed behind the radiator, on the engine side, to ensure that 100% of the radiator's core surface area is used to cool the engine.
If you are building your own electric fan shroud, you may want to consider the type of material you will be using. Some people choose to use aluminium, bending and cutting it to mount the shroud and fan. It is recommended to use the thickest gauge of aluminium that can be comfortably worked with hand tools.
Additionally, when assembling the fan and shroud, it is important to consider the type of fan you are using. Puller fans are more effective with shrouds, as they create a low-pressure area behind the radiator core, causing air to flow through the entire surface. On the other hand, pusher fans with shrouds do not change the flow pattern significantly, so most of the air is blown through the fan rather than the radiator.
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Installation: Shrouds can be attached with rivets and sheet metal screws
Shrouds can be attached using rivets and sheet metal screws. The process of installing a fan shroud involves several steps and considerations to ensure a secure and functional installation.
Firstly, it is important to determine the type of radiator you have. Some radiators, such as those from Engineered Cooling Products, have side flanges that facilitate shroud mounting. If your radiator has a smooth flange with no bolt holes, you may need to get creative. One option is to weld metal to the flange and drill holes for clips or washers.
When using rivets, consider the material and placement of the rivets. For aluminium shrouds, it is recommended to use steel pop rivets and stagger the rivet pattern to improve aesthetics and structural integrity. Scuff the metal at the bond joint and apply a small amount of JB weld between the pieces for added security. Use larger tabs with more rivets to increase the surface area and improve the strength of the joint.
Sheet metal screws can also be used for installation. Small metal screws are recommended, and you can use cardboard to protect your hands and the radiator fins during installation.
Additionally, consider the configuration of your fan. While a pusher configuration is possible, it is generally recommended to avoid this setup as it can restrict airflow through the radiator. A puller fan with the shroud on the engine side of the radiator is often preferred.
Finally, ensure that your fan is centred within the shroud and that there is adequate clearance for the fan blades. This can be achieved by creating a wooden buck and measuring the clearance required for the fan.
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Function: Electric fans are more efficient with shrouds, but shrouds can restrict airflow at high speeds
Electric fans are more efficient with shrouds, which direct airflow and ensure the car doesn't overheat in stop-and-go traffic. However, shrouds can restrict airflow at high speeds, so it's important to consider the intended use of the fan. For example, in off-road or extreme conditions, a fan shroud may not be necessary, as the priority is to maximise airflow to keep the vehicle cool.
When building an electric fan shroud, it's important to consider the material thickness and ease of workability. Aluminium is a popular choice due to its lightness and ease of workability with simple hand tools. It's recommended to use the thickest gauge of aluminium that can still be worked by hand, ensuring minimal flexing while maintaining ease of use.
Additionally, the design of the shroud is crucial. Some shrouds have flapper doors or openings that can be shut at high speeds to reduce airflow restriction. The placement of the shroud in relation to the radiator core is also important, with the recommendation being to keep the shroud as far from the radiator core as possible.
Overall, when building an electric fan shroud, it's important to strike a balance between maximising efficiency at low speeds and minimising airflow restriction at high speeds. This can be achieved through careful material selection, shroud design, and placement in relation to the radiator core.
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Frequently asked questions
Aluminium is a good option for an electric fan shroud, as it is lightweight and easy to work with using basic tools.
The thickness of the material will depend on the tools you have available and your skill level. It is recommended to use the thickest gauge that you are comfortable working with, ensuring it is thick enough that it cannot be bent easily with your fingers.
Fan shrouds improve the efficiency of puller fans and help prevent the car from overheating in stop-and-go traffic with the air conditioning on.
Some common combinations include the Ford Taurus fan and shroud, which are popular in the Jeep, Buggy, and Offroad community, as well as the Volvo 940 and 960, which are self-contained and have built-in relays and sensors.
