Okay so I've been away from RCC for a bit and gotten little done on the car. Too much traveling and family stuff in the summer
I finally got the brake issue sorted out. I'm not sure it was something with the Raybestos MC but I ended up replacing it with a Centric MC, bled that, and reinstalled:
Pedal feel is better, but still not perfect. Either way, time to move on and I'll deal with again when the car is running so I can judge the feel with the booster working. Only new plan at this point is to make a MC brace and a pedal assembly brace as I can see both of them moving a little when bearing down hard.
The next task is getting the fiberglass fan shroud made. After some iterating I came up with a design I liked and get the frame made:
The fan mounting flange is actually on an angle:
The current plan is to have the taller end at the bottom of the radiator in an attempt to exhaust the air through the hood vent. I wanted to duct it but it looks like the water pump pulley and upper radiator hose are going to be in the way. If I run into other interference issues (front swaybar) I can always flip the shroud for more horizontal flow over the engine.
The next step is to stretch, glue, and staple fleece over the frame. I'll be turning this into a mold or "buck" so the fleece won't be integral to the final part. I'm thinking two or three layers of FG for most of the shroud with the mounting areas reinforced with another. I'm also looking into DIY vacuum forming for a stronger/lighter finished product.