68 GT convertible project
While the shroud was off being welded, I turned my attention to the alternator and engine accessories. Since I wasn't using an electric fan, I was able to get away with a smaller amperage Denso alt. This one is a 65 amp version and fits the space very nicely. I was able to make my aftermarket billet brackets work by making custom length spacers on the main pivot bolt. I still need to figure out what to do about a cover for the alt pulley. It looks ugly at the moment with no cover. As you can see, I also decided to stay with power steering and bought the corresponding brackets. The Dart originally came with a Federal PS pump but the brackets are designed for a Saginaw pump.
Once I got the shroud back, I had to figure out an accurate way to cut out the fan hole. I knew if I tried doing it free hand, I would be upset with the results. I did some checking online and found a Youtube video on how to make a circle cutting jig. It was a simple concept and it seemed like it would work well. Basically, the jig mounts to a hand held router. There is an adjustable center pivot bolt so you can set it to the exact radius you need.
First I made a crude little apparatus to find the exact center of where the hole needed to be. The bolt just extended out from the center of the water pump and made a mark on the shroud in the right location.
Once the center was found, I was ready to cut the hole. Here is the jig/router set up on the shroud, ready to start cutting.
We made three separate shallow passes, going a little deeper on each pass in order to get through the work piece.
It couldn't have worked better! The hole is perfectly round. The directions that came with my fan called for 3/4" clearance around the outside of the fan blades so the hole diameter is 16.5".
While the shroud was off being welded, I turned my attention to the alternator and engine accessories. Since I wasn't using an electric fan, I was able to get away with a smaller amperage Denso alt. This one is a 65 amp version and fits the space very nicely. I was able to make my aftermarket billet brackets work by making custom length spacers on the main pivot bolt. I still need to figure out what to do about a cover for the alt pulley. It looks ugly at the moment with no cover. As you can see, I also decided to stay with power steering and bought the corresponding brackets. The Dart originally came with a Federal PS pump but the brackets are designed for a Saginaw pump.
Once I got the shroud back, I had to figure out an accurate way to cut out the fan hole. I knew if I tried doing it free hand, I would be upset with the results. I did some checking online and found a Youtube video on how to make a circle cutting jig. It was a simple concept and it seemed like it would work well. Basically, the jig mounts to a hand held router. There is an adjustable center pivot bolt so you can set it to the exact radius you need.
First I made a crude little apparatus to find the exact center of where the hole needed to be. The bolt just extended out from the center of the water pump and made a mark on the shroud in the right location.
Once the center was found, I was ready to cut the hole. Here is the jig/router set up on the shroud, ready to start cutting.
We made three separate shallow passes, going a little deeper on each pass in order to get through the work piece.
It couldn't have worked better! The hole is perfectly round. The directions that came with my fan called for 3/4" clearance around the outside of the fan blades so the hole diameter is 16.5".