To recap, the '95 Ford T-Bird fan I chose to cool the Performance Only beast was too long in one direction. The bottom needed to get whacked off, and sealed up. I also cut off the unneeded top brackets.



Bottom hacked off with my air body saw. Edges made straight with a 6" orbital sander.



I made a cardboard template that would represent the sheet metal cover.




Cut, formed, pop riveted and painted. I covered all of the edges of the shroud with plastic car door edge guarding, to help protect the radiator fins. I'm currently building brackets so I can mount this fan to the rad.