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Fang16 08-17-2016 11:30 AM

Plastic, ABS repair- fan shroud
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Was looking for ways to modify a ford fan shroud (Lincoln Mark viii) and ran across this site.
Identify Plastics

My radiator is 19"x19" and I need to reduce the size of the shroud (Mark VIII style fan is 21 5/8 wide, 18 1/2 high, and 4 3/4 thick). My idea is to trim the long sides of the shroud down to the required size by removing the excess width and glue or weld the sides of the shroud back on leaving the square box as seen in the picture. Am thinking the depth of the box would be right or maybe trimming the depth if the setup proves to be to thick.

Question is: What method to use short of buying a plastic welder. Which I though a joke until reading the above page.

ntfday 08-17-2016 11:56 AM

After spending 18 1/2 years working for a plastic manufacturer plastic welders aren't the greatest and expensive for what you are attempting. I would suggest cutting it down to size and piece it back together by any means and using it for a mold to make one from glass. Another option would be to fabricate one from sheet aluminum.

techinspector1 08-17-2016 12:34 PM


Originally Posted by ntfday (Post 3851113)
Another option would be to fabricate one from sheet aluminum.

That's what I would do, just build a an aluminum box from sheet, held together with pop rivets and a hole cut out of the back of it to fit half the depth of the fan blade(s) into. Do you have any friends with a sheet metal brake? If not, a HVAC shop in your town will be able to bend up the pieces for you for cheap.

Fang16 08-17-2016 01:20 PM

Thanks to both of you for your reply's. I have a friend with a bench mount brake. Not sure yet how to mount the fan onto the aluminum shroud. Never was any good at fab-ing things up but experience is the best teacher. flop flop, bang bang. lol

ntfday 08-17-2016 01:48 PM

I think you'll be a lot happier with one constructed from aluminum than you would be from a pieced together one from ABS. You can use something similar to these to mount it with. 10pcs 25x25mm Zinc Plated Corner Brace Right Angle Bracket Woodwork L Shape | eBay

Fang16 08-17-2016 02:04 PM

That looks like a good idea but still stumped as to how to mount the fan to the shroud once the hole has been cut. Maybe place the fan inside of the shroud and attach it to the shroud with pop rivets? After trimming down the plastic fan to just enough to mount the fan?

ntfday 08-17-2016 02:42 PM

It appears that the fan and shroud are all one assembly. If that's true I would cut the outside edge off using a Dremel type tool with a cut off wheel and going very slow. You could then adapt that to the aluminum one.

Fang16 08-17-2016 02:50 PM

That was what I was thinking. Luv my dremel tool. lol Is riveting it inside the aluminum shroud a good idea?

ntfday 08-17-2016 03:55 PM

I don't think you'll have a problem with that, but drill slowly through the ABS with a good sharp drill bit. IMHO, ABS is one of the harder blends of plastic to work with.

delawarebill 08-18-2016 08:13 AM

i'll go out on a limb..
when i had my '66 fairlane the center console was cracked in half. i found this on a web site and it was cheap to try and worked well.
where u can't see the repair... sand with 80 paper, use the fiberglass dry wall tape(sticky backed stuff) to hold both pc's together, sprinkle with baking soda to cover tape(don't pile it on) then drip super glue onto the backing soda and fiberglass tape till saturated. let it harden.
i mainly did this for u can't buy a replacement and one that is even broken is $700 bucks. i had nothing to lose and like i said it worked.

Fang16 08-18-2016 08:31 AM

Now that's one for the books!

S10xGN 08-18-2016 10:11 AM

3 Attachment(s)
I actually had pretty fair luck cutting and welding the Taurus fan for my Rambler project. Here's a (purloined Google) pic of the stock fan:

Here you can see the "bumpy stuff" hacked off and about 2" trimmed from one side. All done with ABS rod and a cheap HF welder that, by the way, is a flaming POS. I'm not sure, but I'd even consider trying a small butane torch and spatula, or even an old clothes iron too...


Fang16 08-18-2016 11:04 AM

Thanks for the pix and info. Looks pretty good! I have a friend that is a pro welder. May give him something to do. lol How do you plan on mounting the shroud to the rad?

S10xGN 08-19-2016 08:18 AM

2 Attachment(s)

Originally Posted by Fang16 (Post 3852745)
Thanks for the pix and info. Looks pretty good! I have a friend that is a pro welder. May give him something to do. lol How do you plan on mounting the shroud to the rad?

Not really sure yet, just wanted to get a closer fit to the radiator. There are some bosses on the under side. On my Maverick, I used aluminum tabs welded to the top support and steel tabs on the bottom support. But that fan (Buick GN) fit better and had mounting holes already in good places...


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