I finished making my fan shroud and thought I would post how I did it and what it looks like. Since I don't know how to post pictures with words attached I will post a few attachments to this.
First picture shows the framework that I wrapped the fleece around. As you can see, I added about an inch to the lower panel. I screwed up the first shroud because I made it too small and the fan would touch. The fan I have is a 17" so I made the circular board 18" diameter. The shroud is 2 1/2" deep.
Second picture is the aluminum foil applied to the frame. Fiberglas resin won't stick to that. Forget the foil and it will never come off.
Third pic is me stapling the fleece to the frame.
Fourth shows the fleece stapled. You have to pull the fleece down tight to form to the frame mold.
Last pic is the resin and hardener. Bought them at Lowes. About half the price of an auto shop store.
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