1970 Duster project in Sweden

Thanks for the kudos. Any grade A cotton fabric will work, I just used what I had. Tee shirt had weld pop burn holes in the front. The back was perfect and no holes. Just right size for a shroud. I used cut wooden blocks to make the spacer from the round disc to the radiator side. I screwed them in multiple places around the perimeter to hold the disc up. Notice how the fan hole is offset in the shroud like the repop one you showed, because the engine is offset to the right. I stapled the Tee shirt fabric tightly to the back side of the frame to make sure theres no wrinkles. I ended up using wire to pull it tighter.

Putting about 5 layers of resin on the front will make it stiff enough to pop from the mould and maintain its shape with just the resin and fabric. If you put more, that's even better. This allows you to able to final machine sand without hitting the fabric. When you put the fiberglass on the inside, what I did was screw it down to the plywood work table top with drywall self tapping screws and wide washers in the circular part to hold it flat, then fiberglass the inside. Also make the mould to where your fan is I believe half in and half out of the shroud. This helps with scavenging.

I cant wait to see what yours looks like when done. Take your time between resin coats and let it dry thoroughly before scuffing and applying more resin. Once you primer, sand and paint, nobody will ever know.