DIY Roof Rack Wind Deflector using PVC Foamboard

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I realized I didn't post the link for the follow up video. See it here:
• Diy Wind Deflector - 1...
I built this wind deflector (fairing) using PVC foam board. Same stuff I used for the interior panels of the Wagoneer. I used the brackets from an old Thule I had, but may end up going with some aluminum stock instead.
Painted with bedliner.
Saved about $200 over a AEV or Rhino Rack one. I also cod find any cheap ABS or Poly sheets big enough that didn't cost over $100.

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28 июл 2024

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Комментарии : 59

@FOURWHEELTRENDS 4 года назад

Now you have me thinking of all kinds of useable applications for that kind of board.

@comfort_in_discomfort 4 года назад

Super easy to work with. I can't say how durable it will be as it won't take a lot of impact, but I think this is a good application. Interior trim like door cards. Use it as a base structure for fiberglass projects... I'm going to play around and see what else it can do.

@FOURWHEELTRENDS 4 года назад

Comfort in Discomfort - I have used thick ABS for similar projects and it has held up well.

@raymondclark1785 Год назад

I used it to make slats to replace the glass in my daughters jalocee bathroom window

@laggardly6201 3 года назад

Thanks man ! I was really struggling trying to find the right material and this is it ! I have a home made rack system for solar panels on a Dodge Sprinter . This will do nicely.

@comfort_in_discomfort 3 года назад

Take a look at my follow up video. It didn't work, but I know why. It warped badly after a year in the sun. I think it would work if it's supported better. Maybe a c-chamnel aluminum.

@FOURWHEELTRENDS 4 года назад

First, awesome find on the rack. Second, great job building the wind deflector.

@comfort_in_discomfort 4 года назад

I got lucky for sure. The ad was only for the platform which I wanted an was going to use with gutter mounts. But the guy had brackets and he didn't know what they were for. I told him but he had no use for it... I have about 500mi with the deflector on so far. Makes a noticeable improvement. I may redo a few things, we'll see. Curious how the material will do in the heat in spring and summer.

@alexitosonixx8737 4 месяца назад

Very Creative we can save more than 100 bucks great Idea thanks

@BilleEliott 7 месяцев назад

Good custom work!

@diel1764 17 дней назад

nice work mate

@isshinryu11 Год назад

Thanks!! I will do this! Slick idea!

@FOURWHEELTRENDS 4 года назад

Since you already know about 001. I have to admit. It feels REALLY odd having an empty garage to park in at the house. I have a buddy who’s bartering labor with me working on the brakes, power steering and few other odds and ends. Hopefully I will have it at the house soon before it gets too cold to enjoy being in the garage. Also have a 94 YJ on the horizon. I had a 93 that I sold to buy my wife’s wedding ring. Thought I should get another one for nostalgia.

@bryansprenger 9 месяцев назад

Thank you for the material description and where to purchase. I need to make one and been looking around for what material to use.

@comfort_in_discomfort 9 месяцев назад

I'm glad you found some value in it. After a year, the coating looked great, but structurally, the deflector warped badly. I think if I used an aluminum channel or maybe just one layer, it would have been better.

@wepopcreative 3 года назад

Great job man 😊 wish I had those skills

@mjremy2605 Год назад

Wishing never made anything happen. You are not born with skills. Start doing it. That is how you learn.

@liverenders 2 года назад

Awesome. Exactly what I was thinking of building

@comfort_in_discomfort 2 года назад

It worked great in terms of noise reduction. Watch the follow up video. The material wasn't durable enough for heat and UV. Warped badly.

@liverenders 2 года назад

@@comfort_in_discomfort ohh gotchya that's good to know

@yasfam3700 Год назад

Cool. I need to make one like that also but higher. I went 5000km going and return from uae to saudi arabia. Open space and high wind in desert area will mess cargo on the roof

@VANESSASVANLIFEJOURNEY 3 года назад

*love this idea*

@comfort_in_discomfort 3 года назад

I made a follow up video. The material wasn't suitable for the heat / Uv. Or maybe it was the way i glued it or mounted it. But after a year it was badtyd warped.

@jorgehuamanmusic 3 года назад

You really have me thinking about what I can do with this material. I'm thinking adding fiberglass to it and making it the roof of my roof top tent project. I also wonder if sealing it with epoxy would have helped as far as durability/rigidity and protecting it from the elements? Anyway, awesome idea!

@comfort_in_discomfort 3 года назад

I think the fact I laminated two pieces together was a problem also. Having one expand more in direct exposure while the one in the back was cooler...maybe. But I think it would be great as a middle layer. I may have to try that.

@RENTFREEVANPLAN 3 года назад

It looks great. I think I'm going to try this, although I don't think I have a way to make the angle brackets. My thought is I can use a long aluminum door hinge and use VHB to tape it to the roof and tape the other half the of the hinge to this foam board material.

@comfort_in_discomfort 3 года назад

Don't do it. Check out the follow-up video after a year. It didn't hold up to the sun. Warped badly.

@comfort_in_discomfort 3 года назад

Don't do it. Check out the follow-up video after a year. It didn't hold up in the sun. Warped badly.

@OldManHuggins 2 года назад

Thank you.

@mjremy2605 Год назад

Wow, this is very innovative! Looks strong and light, perfect for RVs! I have a couple of questions: 1. If its too short lengthwise, how can you glue two segments together to make it longer? My Class C RV is about 8 ft wide. 2. 3:17 - what are those curved latches/hardware attached to the fairing? I missed that bit. Where did you get those supports? That is the key to success. Love that final finish you gave it! Looks solid and very attractive.

@comfort_in_discomfort Год назад

I had high hopes for the material. Regrettably, it warped badly in the sumer heat and UV. The finish was fine, but the substrate looked very bad (look for my follow up video). I have since used marine grade plywood and used the same spray on finish. Doing this allows for longer length as well.

@functionalvanconversion4284 3 года назад

Nice video! I am thinking of increasing the size of my Yakima fairing from 48" x 5" to 69" x 8" to match the width of my roof rack. Do you think sandwiching two pieces of this board will work using the old brackets like you did? I will need to make two additional brackets for the extra width of mine. Your thoughts? Thanks for sharing!

@comfort_in_discomfort 3 года назад

Unfortunately this design didn't work long term. It warped pretty badly (follow up video on my channel). I think that the concept is good, but I think the material needs a C-channel on the long ends to keep it rigid. I tried to find plexiglass or polycarbonate that was wide enough, but only big sheets. I'm going to try again with a different support system. The spray on rubber coating was great.

@functionalvanconversion4284 3 года назад

Thanks for letting me know. I originally had a challenge finding a material a few years back which is why I bought an undersized fairing from Yakima. I'll check out your other video. Thanks for your time!

@febsie 3 года назад

You think I can use something like this for the roof top tent fitted to the roof rack? The tent is a bit boxy so the drag is unreal and so is the noise!

@comfort_in_discomfort 3 года назад

If you watch the follow-up video, you'll see that the material didn't stand up to the heat/UV. Got about 6 months out of it and it warped to hell. However, the concept should work with a roof top tent for sure. Polycarbonate, plexiglass, metal... but sadly this material isn't suitable.

@user-gj8mn4ce8d 3 месяца назад

Just one question, doesn’t having that half inch or less opening on the bottom cause any issues with whistling on the highway ?

@comfort_in_discomfort 3 месяца назад

It was much quieter than before. I didn't want contact with the roof for fear of vibration and damage. So while I had it it was great. Unfortunately, as you'll see in the follow up video, it warped badly. Could be my construction technique as I laminated two panels. One expanded in the sun, while the other didn't.

@bradmelvin7187 4 года назад

Thanks, awesome job!

@comfort_in_discomfort 4 года назад

I'm glad it was of some use. It's been holding up well. The tips are curling slightly so I may put a small aluminum channel and rivet it.

@yrebrac 3 года назад

nice job

@comfort_in_discomfort 3 года назад

Thanks. I wish it had lasted. I posted a follow-up. It warped badly. I think because I glued two pieces and they expanded at different rates and because I didn't support them well. I think the next one I'll use a piece of angle channel and it should be good.

@yrebrac 3 года назад

@@comfort_in_discomfort Good to know! I'm currently using a piece of pine as a POC which has also warped, I suspect due to water. Did you consider plain PVC/polycarb flat sheets?

@comfort_in_discomfort 3 года назад

@@yrebrac I think the next one will be a polycarbonate sheet. Thus happened to be material I had as I used it to make door cards for my wagoneer and it's perfect for that.

@miguelcintron6595 4 года назад

ANY UP DATE OF THE WIND DEFLECTOR SO FAR - GOOD IDEA

@comfort_in_discomfort 4 года назад

The coating is holding up great. The wind deflector tips have warped only slightly. I may put in a small C-channel behind it to reinforce, but it's been good.

@allencoin 3 года назад

Looks awesome. Is it still holding up for you over a year later?

@comfort_in_discomfort 3 года назад

No unfortunately. I made a follow-up video. It warped badly, though I think it's because I laminated two pieces and didn't support it well. I think this material is great, but the next version needs an aluminum C-channel. The rubber coating did fine.

@allencoin 3 года назад

@@comfort_in_discomfort Thanks for the reply! Sorry, I didn't see the followup video. I'm researching building my own DIY wind fairing for my roofrack. This is extremely helpful info. Thank you.

@comfort_in_discomfort 3 года назад

@@allencoin Good luck. I will likely try again, this time with a bit more support, and planning...

@DanielMiller82 2 года назад

How is this holding up nearly 2 years later?

@comfort_in_discomfort 2 года назад

Not well. I made a follow-up video. 12 month failure. Warped badly. I think laminating two sections was a mistake as one gets direct heat, the other does not. And I should have supported the whole length with a c-channel.

@jaybeeflorendo466 Год назад

What kind of roof rack do you have?

@comfort_in_discomfort Год назад

I still have a Baja platform rack on my son's JK jeep. Unfortunately the material for the deflector is really not as stable in uv and heat as I had hoped. The follow-up video shows that it really warped after 2 yrs. I may re-do it with some aluminum reinforcement.

@kconatymd 3 года назад

would have been nice if you provided a link

@comfort_in_discomfort 3 года назад

To the pvc board? It's a ceiling tile I bought at Lowes. However, the follow-up video of a year later shows a compete fail. Wouldn't suggest it for high UV exposure.

@travato1592 3 года назад

@@comfort_in_discomfort ha! OK thanks!

@JoseGonzalez-jt1tt 2 года назад

Nice work 👍, maybe should have gone a little bit wider.

@comfort_in_discomfort 2 года назад

For sure. The Jeep roof is 52" wide. Unfortunately the panel I had was only 48. Next time I'll use a different material as well as making it bigger. This material warped badly (see follow-up vid)