3.0l Engine Rebuild
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3.0 Rebuild | Diagnosis | Teardown | Shroud | Prep

Patching Holes

Masked shroud connection to top of fan surround

Washer used to pattern top repair sheet

Fiberglass weave sheet test fit

Resin mixture applied

Patch dried with mask removed

The worst break was in the hole that connects the shroud to the fan surround. It was completely broken through. Fixing it would be a multi-step process:

  1. Masking
  2. Filling
  3. Shaping
  4. Final Sanding

First, a wax paper mask was placed such that it covers the bottom plane of the hole that is to be filled. This mask will give the fiberglass resin and particles a non-stick surface to rest upon while drying. It will also create a nice flat surface on the bottom of the patch so less sanding will be required.

The edges of the original shroud were roughed up with 80 grit sand paper to give the resin a good hold on to the existing structure. Then a mixture of resin and cut fibers was put in an old yogurt cup. The fibers were cut no larger than 1/4 inch long and thoroughly mixed in with the resin.

A repair sheet of fiberglass weave, commonly available, was cut using a washer as a pattern. The washer was a perfect round matching the existing shroud.

The mixture was spread across the opening of the hole and shaped to replace the lost portions of material. Then the repair sheet was put on top and more resin mixture was spread around the edges of the sheet. When the entire sheet is saturated with resin it will turn translucent.

After an overnight dry the resin is solid as a rock. The wax paper comes off easily and the surface is shiny.

Shroud Part: 1 2 3 4

© 2006 RHO Design