Windscreen for roof bars - custom build

Taking inspiration from this design build on YouTube:
https://www.youtube.com/watch?v=gtcsS5foO9g
I've started on our windscreen for the front roof bar on our Sprinter camper. We don't have any issues with wind noise, but I wanted to see if it would make a difference and help push air over the solar panels mounted to the roof when we were on the road.

The angle and placement had to be just right to get the angle over where the cables from the solar panels go into the roof via the IP66 junction box.

Uprights are stainless steel, plastic is from a sheet I had in the garage (doubled up for strength), fittings are stainless, stainless pipe clamps with nylock nuts to the rear.

I wanted to avoid having to form the screen around the roof ridges so I'm intending for the dam/windscreen to butt up against the roof just ahead of the ridges. Looking at the angle of the front of the vehicle this looks to work aerodynamically.

We have Thule 766 bars which are approximately 20mm square and 30mm pipe clamps look to fit perfectly.

Plastic has been heated up with the old handy heat gun and bent to shape. It needs some more work tomorrow, most likely bending over some angle bar to perfect the angle and a cross support running behind all five uprights to keep it all perfectly straight.

Didn't get to quite finish it today and SWMBO was unimpressed that I wasn't making dinner for everyone and out in my overalls again!

Looks like an interesting project.

I didn't watch the entire video.

Was anything mentioned about the front edge contacting the painted roof surface? I'd be concerned that eventually the paint will rub through and rust. Grit is bound to get trapped which could accelerate the problem.

An off the top of my head solution would be to glue a plastic strip or EPDM roof membrane strip across the roof as a bearing surface. That should prevent paint damage.

vic

Yes, that's the plan, just haven't decided on the tape type yet

The very expensive Thule kits you can buy off the shelf come with some thick clear stick on tape that does just that. I've got a rubber trim piece over the edge of the plastic and I'm keeping the metalwork away from the roof for the obvious reasons.

Edit: UHMW tape is apparently the stuff: http://embossingtapesupplies.com.au/uhmw-tape-slick-surface-tape.html

Arnie_Oli said:

Yes, that's the plan, just haven't decided on the tape type yet

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Tedlar tape that is used for pipe insulation and such might be a good choice. It holds up to weather and UV very well. Once stuck to a clean surface it stays pretty much forever.

Man. The price sure has gone up. I'm going to be more careful with my hoard of it.

https://www.eis-inc.com/film-tape/p-3m838x1.5

One method may be to stop by an insulating company and ask if you can use a bit off a roll right there and pay them for it. I know that it will last.

Millionaire's tape might work well too.

http://www.apsltd.com/aps-advisor/wrap-it-up/

Radius any corners on the tape. Square corners encourage the tape to lift.

vic

I have a nice roll of that Tevlar stuff I believe as I was using it to bond the insulation sheets together.