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Thread: Building a blower motor to air duct adapter

  1. #1
    Senior Member Brett's Avatar
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    Building a blower motor to air duct adapter

    If you have kept up with my fresh air vent project you know I decided not to go with an in-line blower because of the noise and now going with an Mercedes oem blower motor that they use in their center consoles.

    Well the blower housing has a square opening and the air duct line is round so an adapter has to be made since no one makes one.

    First I removed the motor and fan so I only have the housing to work with. Next the tabs were cut off since I wont need those.
    P8200001a.jpg

    After I sealed the section of housing I wanted to make the adapter for I waxed it and put a layer of PVA.
    I used some PVC pipe for the square flange of the blower to transition into and used masking tape to hold it in place. The PVC pipe o.d. is smaller than the air duct i.d. to allow for the build up layers of fiberglass to match the i.d of the air duct
    Next I used aluminum tape to hold the expanding foam in place while it cures.
    P8210002.jpg

    P8210003.jpg

    After curing over night the foil tape is removed
    P8210004.jpg

    I used a hack saw blade to remove the large cuts
    P8210005.jpg

    Then using rough to fine sand paper I started shaping.
    More later.

  2. #2
    Senior Member Brett's Avatar
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    Adapter sanded to desired shape
    P8220001.jpg

    P8220002.jpg

    Adapter sealed and a few coats of primer sprayed on
    P8220003.jpg

    Final coat of black paint applied.
    P8220004.jpg

    Once the paint has cured I'll put a few applications of wax on and then PVA will be applied.

    This is the mould. I want the interior surface to be smooth.

  3. #3
    ***Euro-Nova Supporter***
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    Top work there

    This why the term kit car does not really apply to the Nova,
    if it is a kit, why are we fabricating entire subsystems, dashboards, chassis mounts from scratch?

    Good to see you forging ahead, keep the updates coming.

  4. #4
    Senior Member Brett's Avatar
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    One adapter semi done

    P8240001.jpg

    P8240002.jpg

  5. #5
    ***Euro-Nova Supporter*** Peter's Avatar
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    All I need is a couple of 45 degree 63mm m/fm elbows . absolute bugger to find.
    The opinions expressed in my posts may not be made in a sound mind and should be taken in the spirit intended, Jack Daniels is fine.
    Some people see things as they are and ask why? I dream things that never were and ask, why not?” JFK
    Genuine and an original, "Grumpy old mechanic".

    http://ukhozi.page.tl

  6. #6
    ***Euro-Nova Supporter*** BlueNova's Avatar
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    Quote Originally Posted by Brett View Post
    One adapter semi done

    P8240001.jpg

    P8240002.jpg
    .... who needs 3D printers?

    Excellent work!

  7. #7
    Senior Member Brett's Avatar
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    Quote Originally Posted by BlueNova View Post
    .... who needs 3D printers?

    Excellent work!
    Thats how you do it the old school way. Before there was computers and programs and machines to do the work for you.

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