by Ian Linden » Tue Apr 29, 2003 21:36
[u:9988776655]Brian Murphy's instructions for Making a Windbreaker:[/u:9988776655]
I thought initially that something solid would be easy to fashion and toyed with cardboard but it would cut-out rear vision. Then Perspex came to mind. However, my wife was against this material as she had experience of the shards produced by broken Perspex. So something stronger. I contacted a plastics company (DIY Plastics) and asked their advice and they suggested using a polycarbonate sheeting which was available in various thickness (3mm, 4mm and 6mm) and was the same material used for riot shields and helmet visors. Although a lot more expensive (£37.65 delivered) than ordinary plastics it filled the criterion. Before proceeding further, a cardboard template was made of the proposed screen and proved invaluable.
I purchased a 36"x24", 3mm thick sheet which arrived within a few days.
Cutting the shape was easy using an electric fret saw, and using a surform and file finished the task. To finish the job all the edges were trimmed with black plastic edging, as used on door edges to stop chipping when opening the doors, available from motor accessory shops, in a roll. As it is some half inch wide it is too thick to go around the radius corners. I cut a strip to the required length to go around the sheet and trimmed it down to roughly half its width (1/4") which made it easier to manage.To mould it around the radius corners I heated the area, on the strip, in a bowl of hot water. It may save you some time. Secure the strip with a little household glue.
In my case the finished article needed to be removable. Now came the task of fitting it and after various experiments it looked as though the simplest and most effective method would be to make two straps, to loop around the headrest posts. The windbreaker could he fixed permanently, but this would make entry to the rear shelf almost impossible when the roof was in situ.
Now to see if it worked. Although the plastic thickness I had chosen seemed to bend a little too much at speed, it did stop the draught and just needed a bit more fine tuning. It was bending too much in the wind; so to cure this another fixing point was made at the junction with the U shaped bracket that carries the seat belts. One detachable fixing on both sides cured this problem and it was also found that the using the thinner plastic
sheeting had paid dividends for it allowed the windbreak to bend and shape better to the backs of the seats. Using a thicker plastic may have other benefits, but its debatable.
Fitting a windbreak has certainly improved the comfort factor when the roof is off, as there is no cold wind lashing around between the seat backs. A worthwhile task and simple to make. (If I can do it, anyone can).
D.I.Y. Plastics (UK) Ltd., Regal Way, Faringdon, Oxfordshire, SN7 7XD)
email: sales@diyplastics.co.uk Tel:0870 444 2622
There y'go, and thanks Brian, for sharing it :D
EDIT: Scroll down for some pictures
SCORE Treasurer & Membership Secretary