As posted previously, my plastic fan shroud repop did not work with the original 6 blade 19" fan and fan clutch for the A/C 442. The diameter of the shroud opening was 19.75", and slightly rubbed on the bottom. Till now I was using an 18" fan with no clutch.
But I wanted all the original parts so looked for a way to make it fit. Turns out the shroud has a 3/8" turned-in lip at the opening that turned towards the fan blades. A photo I obtained from an original plastic shroud (from this website) showed no turned-in lip, the opening edge was simply straight.
By trimming the lip I would increase the diameter of the opening by 3/4", enough I presumed to make it all fit. My idea was to use a small router/trimmer with a flush-cut trim bit made for cutting plastics.
My first attempt at trying to trim the plastic was shaky as the plastic did not cut easily; it would shatter instead of cutting smoothly. To try and get a smooth cut I cut some flexible wood strips to place inside the lip so the router bit could only cut about a 1/8" of material instead of trying to cut 3/8". This worked much better. After each pass around I would remove a strip, until I was guiding the router just using the shroud itself. It came perfectly smooth and flat.
Installed the shroud and now the original 19" fan blade and clutch fit.
Last Edit: May 22, 2020 19:44:46 GMT -5 by RIP OLDS
If you are trying to stay original, where did you come up with the 6 blade fan and a clutch idea? I have owned a few bone stock air conditioned 65 442's and all of them had the 4 blade fan and only two had the full shroud. The others had the plain metal ring. Don't take this wrong, I don't claim to know everything, I have simply never seen that configuration come out of the factory. Please correct me if i'm wrong and I'll make an addition to my web page. I would like to see the confirming documentation if you have it.
I use the assembly manual and service manual for reference, in addition to some original photos of my car and other AC cars. It seems pretty clear from the assembly manual the clutch and six blade fan were used on AC cars. I could be wrong as well although many members here stated the clutch fan was used on AC cars.
In addition I got all underhood AC parts from an original AC car (my parts were long gone) and the six blade clutch fan came with it.
The metal ring or the plastic shroud were used, probably depending on options. The assembly manual was revised Dec 64 to allow the metal ring on W29 AC cars. I couldn't track down a ring years back so went with the shroud.