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Old 09-03-2009, 07:09 AM   #1
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1969 31' Sovereign
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New Shroud for AC

When I bought my '69 AS it didn't have the bigger AC shroud around the AC unit. Then on my way to AR for a wedding the only remaining cover blew some where down the road. Ugh!
So through some contacts at te local marina I was able to acquire some of the styrofoam they use for floating docks and such. The next part was more of an experiment than anything else, I had to measure twice cut even more times just to make sure I was close to the original as possible. I then had to look online for the how to on fiberglassing. Little did I know that fiberglass resin will eat styrofoam, back tot he internet. Ah, Ha!!!!
To use styrofoam you have have a medium that will not melt, solution wax paper. So, I covered the mold and went to work, albeit not the best looking thing but it works for what I needed.
Round two: Looking online for the bigger shroud and finding it cost way out of my price range I decided to make another mold. Back to the marina, bad news they had some foam but it was to small, ugh. Another source down the road had the huge pieces, my luck held the owner was giving these away. The piece I got was 1 foot thick, 5 feet long, and 4 feet wide. I had to figure how to cut this piece down to size. Chain saw works like cutting butter with a hot knife. After the rough cut and some major smoothing the final piece looks like this.
Next post: Fiber glassing.
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Old 09-03-2009, 07:14 AM   #2
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The ingenuity people display on this forum never ceases to amaze me. Good job, Gary! Keep the pics coming.
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Old 09-03-2009, 08:04 AM   #3
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1969 31' Sovereign
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Fiberglassing

Ok, I am glad of one thing, I did all of this outside, the mess was amazing little foam balls everywhere. But I digress.
After some more smoothing and checking of the positions for the vents on the side I covered the mold in wax paper.
I thought I would use two types of fiberglass (mat and cloth) as well as two different types of resin (jelly and rosin).
After using the jelly i have decided that this stuff is good for filling large gaps and cracks or maybe as a final application. So I stayed with the regular resin. After several layers of fiberglass mat and two layers of cloth the shroud looks like something I can use. In the first two photos I have lifted it off mold to check the interior for cracks or spots that were devoid of resin.Click image for larger version

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ID:	86567 These next two are of the shroud off the mold and have been sanded and are ready for the first coat of Primer.Click image for larger version

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Old 09-03-2009, 08:07 AM   #4
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Primer

Here is the Shroud with three coats of primer, as you can see I just used regular spray paint nothing to fancy.
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Old 09-03-2009, 08:14 AM   #5
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I have to get the photos of the final paint job. I also had to create, make the "Z" channel for the shroud to be attached to. (Thanks to TomW for the photos he provided when he was restoring his Overlander.) I have since then plae the shroud on the AS and it is about 4 inches to long in the back but I think it it is ok. It doesn't have the nice curved edge that the one you can does but I placed an edge guard around the shroud so it doesn't sratch the aluminum.
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Old 09-03-2009, 10:50 AM   #6
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Gary, you might want to keep the mold...people might ask you to make one for them, especially if you can do it cheaper than what it's being sold for elsewhere.

If it weren't for the fact that my shroud is 100% intact, I'd wonder if a 1969 shroud fits on a 1971. You do have an Armstrong A/C, right? Ever notice that the shrouds look different from year to year?

Great job!
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Old 09-03-2009, 03:34 PM   #7
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I made sure I kept the mold for just such an occasion if such a need ever arises.
Supposedly this mold will fit 64-69, according to my sources. And yes it is an Armstrong.
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Old 09-03-2009, 03:46 PM   #8
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How many layers of mat and cloth? How thick did your shroud end up being? Got a picture of the final installation?

Pretty cool btw!

Chris
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Old 09-03-2009, 04:11 PM   #9
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I used two layers of each with the cloth being the final layer. I will have to post a pic when I get back to the house. I'm in the middle of the 30 mile yardsale, have to finance the AS projects somehow, 5 years of collected stuff going to the highest bidder.
I will try and get the finished photos up in a couple of days, the thickness is approx 1/16+/-. I tried to make sure that the wind side was thicker that the rest that way road object will not break through.
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