I did it and it works!!!
Materials list
One sheet of lexan 3/8" thick
Dimentions required 41" x 16"
Additional sheet of 12"x12" if you wish to cover the hole between the seats below the wind baffle.
2 Velcro straps (in stretch material with a plastic loop on it) I used 27"x1" straps made by Velcro USA (band name VelStretch) they come in packs of 2!
Required tools
Elecric drill with a 3/8# drill bit
Flat or orbital sander with 220 grit paper
Jig Saw with a blade to cut plastic
A metal file (fine grit)
Steps to make the wind baffle.
Buy your plastic stock pre-cut and leave the protective film on until you are finished all cutting, drilling and sanding.
1. Round off all 4 corners
I used a rectangular tupperware container with rounded corners to trace the rounded line evenly on all 4 corners.
2. Use the jig saw to cut sharp corners down to rounded corners
3. Sand all edges down, be sure not to have any sharp edges!
4. Identify the top of the wind baffle and mesure down 4 1/2" from the top and 7" from the side for the first strap hole.
5. The strap hole must be 1" wide so from the 7" mark on the side identify the end of the srap hole 1" further.
NOTE!!! Be sure that both srap hole marks are even.
6. Repeat the same operation at the other end of the top of the baffle for the passenger side top strap hole.
7. For the bottom hole of the strap, mesure 5" from the top strap hole of 9 1/2" from the top of the baffle.
NOTE!!!! Be sure to align the marks with the top srap hole marks
8. The bottom strap hole will also be 7" from the side and 1" wide.
9. Repeat the operation for the passenger side bottom strap hole.
10. Drill the lexan at each end of the strap holes, drill start and end of hole.
11. Repeat drilling operation on each of the 4 strap hole marks.
12. Use the jig saw to cut lexan between drilled holes.
NOTE!!! Do not take more material out than 3/8" x 1"
13. Sand down the strap holes to make them smooth and remove any sharp edges using the metal file.
14. Insert the velcro straps starting from the top and what will be the inside to the bottom outside looping the strap back in. Be sure to have the bucke of the velcro strap at the top.
15. Clean off all shavings and sanding residue and remove the plastic protection film from both sides of the lexan.
16. You are now ready to install and adjust your home made wind baffle!!!
For the 12"x12" addon
part, cut, round and sand all 4 corners. This
part can rest between the seats and the baffle and will block off most of the air returning behind the top wind baffle.
TOTAL COST OF THE PROJECT..... 46$cdn or 30$us.
I tested the baffle on the road, and the comments I have to make are about the same as the ones I have seen posted.
1. Works best with windows up
2. Some wind noise coming from the top of the baffle.
3. With windows down you still get some windage coming into the compartment
4. Without the bottom plate between the seats you get alot of drafting entering from between the seats.
5. Easy to install
6. Soft top can come up and down with little or no rub.
7. Little visibility reduction although I did notice some glare when looking in the rear view mirror.
8. It fits the trunk as the width clearance is 41"
Now I need to get the sewing machine out and make a pouch for this thing as it will be easily scratched if left on its own in the trunk.
I have costed the pouch material in a durable cotton, with a velcro lip at about 10$cdn or 6$Uus.
Total labor for this project 1hour. About 1hour will be required for the pouch as I am not very skilled with the sewing machine.
Good luck, if you have questions, dond hesitate and email me.