Alright... so it turns out that I'll be driving my wife's car for the next few days to diagnose a mysterious coolant disappearance, so that gives me the opportunity to go nutty bananas with making this shroud.
This is the moose plow I mentioned earlier. It's all 1/4" plate (the front panel is 5/16") and schedule 80 tubing. It weighs a little over 200 lbs.
Here you can see how it occludes ambient airflow going into my cooling devices.
I first removed the overflow tank and washer fluid tank. I did not empty the overflow tank but I did empty the washer fluid tank. I found it convenient to disconnect the hose in the engine bay, feed it into the wheel well, and use the pump to drain the tank into a gallon bottle. Then disconnect the hose from the pump, and both electrical connectors from the pump and low level sensor.
If you haven't removed the tanks before, they're held captive by protrusions of plastic that snap into holes on the shroud. Jam a screwdriver or something between the tank and the shroud, and lift up. The overflow tank is straightforward, the washer fluid tank is kind of a pain. However, you CAN
get the washer fluid tank out without disconnecting the upper radiator hose. Loosen the shroud and jigger everything around, you'll figure it out.
For the shroud, there are two clips on top of the radiator and 4x 10mm screws on the sides that hold the shroud to the radiator tanks. There are two tabs on the bottom that disengage when you lift the shroud out.
Here's our workspace after removing the shroud. It looks like a lot, but it disappears quick!
Here's the shroud out of the truck.
To keep the tanks in the factory location, we have to pay particular attention to the retaining system and re-create the slots and holes in the shroud. This side is for the washer fluid tank.
This side is for the overflow tank.
We also have to note the relative angles that the mounting surfaces are at.
The shroud will essentially be a shallow box, using the length and width of the core (outside dimensions for the shroud are 36" x 19.625"). I determined the thickness should be 1.25" because the fan protrudes forward of it's housing by just under 1". .25" plus material thickness (.078" in my case) is enough room to have good clearance without taking up excess space. Before everyone starts clamoring for dimensions, I will draw this whole thing up in CAD after it is built and I have worked out any kinks.
I can then provide prints to anyone who wants them.
Now, before I go further, I should disclose to you all that my equipment at home includes MIG and TIG welders, a plasma cutter, a lathe, and a milling machine. So far I haven't had to do anything super exotic while making this shroud, and what I have utilized in the way of equipment you might not have access to has only been to save time or to allow a greater degree of precision. It has not and will not fundamentally alter the design.
In case anyone wants machinery porn:
Now, after I determined what my dimensions were going to be, I burned out the parts for the box. I'm using 14 gauge steel because I have some lying around and I'm not likely to use it for anything else.
Is is just me, or is it hot in here?
Here's the back face of the shroud.
Here's a mockup of fan placement.
Here's the two strips that will make up the top and bottom. The piece these were cut from was left over after I cut the rear face out of a larger piece. This remnant turned out to be exactly wide enough to be for two strips at 1.25" plus the width of the plasma arc. I used my boss layout skills and cut it exactly in half. Boom, baby.
Here's the top and bottom tacked to the rear face.
And here's the sides put on.
Here's a test fit in the truck. It fits so snug in bare metal that powdercoating might make it too tight. I might run a grinder down the sides and slim it up a few thousandths.
Next I made the tabs that secure the bottom of the shroud to the radiator. I decided to true these up in the mill to allow for a more precise fit, that is not necessary though. These tabs are 1" x .875" and .188" thick.
Positioned properly, and with a slight radius ground onto the top (bottom) edges, they fit perfect in the lower radiator slots.
Next I went to work on making the mount for the overflow tank. I had a piece of steel around that was *almost* the right size to begin with. I simply took measurements off the locking tabs on the tank, transferred them on to the steel, burned out the holes, and cleaned it up with a carbide burr. Once I got it to go on and off easily, I mocked it up in the truck, tacked this piece to the side of the shroud, mocked it up again to get the angle right, then made a piece to gusset this mount on top and another to gusset the bottom and serve as the ledge that supports the bottom of the tank.
This is how it came out. Tank fits like it was meant to, and it's sturdy enough to hold up even with just the tacks.
I didn't have enough material to get cracking on the washer fluid tank mount, so I worked on fitting the passenger side fan. I found I would have to trim the overflow tank mount a little, and possibly the back edge of the fan itself (hopefully not, we'll see).
A word to the wise: If you take the blades off of your fan (like I did, to fit the fan without the protruding blades messing up my mockup,) put a hand over the clip when you remove it. This is one of those deals where when it comes off, you hear a "ping!" and it flies into oblivion at the speed of light. You hear it smack against a hard surface across the shop, but you can't be sure of where or what it hit.
Luckily I found mine, because it's not a common clip and I probably would have had to get another one at the junkyard. It's like an e-clip, but it's tapered to hold the fan firmly against the hub, not just to retain it on the shaft.
Also, if you bench test your fan(s), secure them to something and watch your fingers.
They have enough torque to launch themselves off the bench, and those blades move quick! I tested mine with a half-dead car battery and was impressed with the airflow.
As of tonight there are no new Volvos at either yard so no help there, but I should have time tomorrow to find a piece of material to use for the washer tank. I'll be camping for 4 days this coming weekend, I'd like to have the shroud completely done (minus powdercoating) by the time I leave Friday morning.