DIY continue... now need to extend the shroud to cover up the gap..
Now start construct the fan shroud, measure the plate required... place the fan shroud on the floor use the floor as base guide...
<a href="http://www.flickr.com/photos/min-min/5585471816/" title="IMAG0511 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5060/5585471816_a9c547f48b.jpg" width="299" height="500" alt="IMAG0511"></a>
then cut out the plate and rap around the original fan shroud to get detail measurements.
<a href="http://www.flickr.com/photos/min-min/5584841929/" title="IMAG0513 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5252/5584841929_16261b054a.jpg" width="299" height="500" alt="IMAG0513"></a>
<a href="http://www.flickr.com/photos/min-min/5585472198/" title="IMAG0514 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5108/5585472198_b253351dfe.jpg" width="300" height="500" alt="IMAG0514"></a>
<a href="http://www.flickr.com/photos/min-min/5584767415/" title="IMAG0515 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5051/5584767415_1f45d2bc61.jpg" width="300" height="500" alt="IMAG0515"></a>
<a href="http://www.flickr.com/photos/min-min/5584766455/" title="IMAG0518 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5101/5584766455_54caed7958.jpg" width="500" height="300" alt="IMAG0518"></a>
The cut off the plate to fit the original fan shroud.
finished extended shroud
<a href="http://www.flickr.com/photos/min-min/5584766859/" title="IMAG0516 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5147/5584766859_a8b1ed4872.jpg" width="300" height="500" alt="IMAG0516"></a>
---------- Post added at 11:17 PM ---------- 6 hour anti-bump limit - Previous post was at 11:06 PM ----------
now, start rivet the extend shroud to the ori shroud..
--> drill a hole the fit to the rivet. the hole must be fit tight to the rivet, otherwise it will not hold the extend shroud.
<a href="http://www.flickr.com/photos/min-min/5584765227/" title="IMAG0519 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5172/5584765227_bb37a13034.jpg" width="300" height="500" alt="IMAG0519"></a>
<a href="http://www.flickr.com/photos/min-min/5584765105/" title="IMAG0520 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5016/5584765105_ac9cfbabf4.jpg" width="500" height="300" alt="IMAG0520"></a>
use a bigger drill to drill off the excess steel with hand..
<a href="http://www.flickr.com/photos/min-min/5584756485/" title="IMAG0524 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5310/5584756485_eca084f618.jpg" width="300" height="500" alt="IMAG0524"></a>
<a href="http://www.flickr.com/photos/min-min/5585350228/" title="IMAG0521 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5148/5585350228_30d33fb254.jpg" width="300" height="500" alt="IMAG0521"></a>
---------- Post added at 11:21 PM ---------- 6 hour anti-bump limit - Previous post was at 11:17 PM ----------
The extended shroud plate is quite thin... so i hammer down the tagged rivet to further strengthen it...
<a href="http://www.flickr.com/photos/min-min/5584746067/" title="IMAG0528 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5185/5584746067_39bc34b79e.jpg" width="300" height="500" alt="IMAG0528"></a>
like this more firm.
<a href="http://www.flickr.com/photos/min-min/5584745679/" title="IMAG0529 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5229/5584745679_dbc524d461.jpg" width="500" height="300" alt="IMAG0529"></a>
---------- Post added at 11:26 PM ---------- 6 hour anti-bump limit - Previous post was at 11:21 PM ----------
rivet around the shroud to hold it extended part. make sure the extended shroud in the right position before you drill and rivet. again u can use the floor as based to guide the extend shroud when drilling..
finished rivet shroud.
<a href="http://www.flickr.com/photos/min-min/5585336948/" title="IMAG0530 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5299/5585336948_d580a935cc.jpg" width="300" height="500" alt="IMAG0530"></a>
the fan is really oversize... so after put on the intercooler... cut off small part as shown below inorder to let the fan shroud to sit properly on the intercooler.
<a href="http://www.flickr.com/photos/min-min/5585336590/" title="IMAG0531 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5304/5585336590_b87be2518d.jpg" width="300" height="500" alt="IMAG0531"></a>
---------- Post added at 11:34 PM ---------- 6 hour anti-bump limit - Previous post was at 11:26 PM ----------
there are still 2 more area need to cover up at the side of the intercooler...
cut off 2 more steel plate to over it up... for this 2 small plate, i fold the plate in two so that it more firm and strong.
<a href="http://www.flickr.com/photos/min-min/5585333736/" title="IMAG0532 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5225/5585333736_c8c3606e33.jpg" width="300" height="500" alt="IMAG0532"></a>
<a href="http://www.flickr.com/photos/min-min/5584742009/" title="IMAG0533 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5022/5584742009_9736c5cf13.jpg" width="300" height="500" alt="IMAG0533"></a>
place the plate to the position and mark hold for drilling. i use back the same hole that hold the fan shroud to tie the plate.
<a href="http://www.flickr.com/photos/min-min/5585300460/" title="IMAG0534 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5303/5585300460_7820e0a87c.jpg" width="300" height="500" alt="IMAG0534"></a>
then cut off the excess parts so that it easier to install later..
<a href="http://www.flickr.com/photos/min-min/5584708873/" title="IMAG0535 by CheeYeong, on Flickr"><img src="http://farm6.static.flickr.com/5293/5584708873_6bd43639a4.jpg" width="500" height="300" alt="IMAG0535"></a>