ive been looking around, and i cant seem to find a place that has custom made fan shrouds, this might not be possible, but im looking for a 4 120mm fan shroud for my radiator.
i no there HAS to be a way to make it, but im not that creative with tools, and i need some ideas, maybe a little guide on how to make em possibly,

What i usually do in these cases, i get a piece of wood the size of the piece you need, i'm guessing it goes on the rad and has 4-120mm fan holes anyways.

Use the wood as a mold say a 2X4 and use pre cut pieces the size and shape of your fans, nail them on the 2 by where you want the fans and go with fiberglass, the kind used for car body repair, you can add layers on layers to make it as hard as you want and then cut your holes.
You can also cover with bondo to make it smooth and give it the shape you want then paint.

And voila! custom shroud (not without trouble but it gives a sense of acomplishment when done )

you could get some sheet polystyrean from a model shop and cut that up either and fit it to your radiator.

Sorry I didn't reply earlier (to the PM) but sheet metal worked great for me. I used some auto-molding on the dges to make it look clean and it seems to keep the air where it should be.

Looks good but what is holding the fans on the rad, can you show it on the other side?

sure. The fans are screwed to the shroud, and the shroud fits the rad so nicely it is like a solid unit. The shroud "hugs" the top and bottom sections protruding from the rad.

This is the best picture I have, and I can't take more since the unit is installed now..

But I think it gives the idea.

you could make one out of fibreglass resin and nylon:


ProCooling.com - Composite Air Duct

best thing being you can make it quite easily compared to working with sheet metal...

Looks good that's more what i was thinking with fiberglass, but you're right , with the resin all you really need is a good base, even solid stretched cloth could do

I think you should just go get a peace of metal and tin snips and make your own im sure it wouldnt take to long or be that hard just do as shown below on the metal

after doing the cutting just bend all four sides in to meet in the corners

its cool ravix

wow, thx for all the ideas guys, i found some metal sheets laying around the garage the other day, so how would i go about cutting it (got D+ for metalshop in middle school LOL)

and another thing, when i make the shroud, should i leave a space between the rad and the fans? or should i put it flat on top of the radiator

Thats the point of a shroud, to leave a gap. Iunno what the term is but it makes the air go through alot smoother and effectively cooler

got cha


what about space between bottom of rad and the surface your putting it on? need a gap?

Well, the air has to exit the radiator, so yes. The more space for the air to flow, the better.

I'd say 1/2 an inch (10mm) would be sufficient

heyy
look at that, temp dropped 2c! scouts honor!
lol

try and post some pics soon
but as now
from fan to rad i have about inch of space
from rad to surface i have about an in of space as well