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      10-01-2009, 04:55 AM   #1
WAMz4
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Home made windblocker. Heres how I made mine


I started with a piece of 1/4 inch LEXAN 14x24, a 1/4 inch piece of foam board and a strip of 1/4 inch aluminum edge trim.

I cut the edge trim to six inch strips with a metal saw blade and notched them at 2 inch spacing. This allows it to form to the curve of the roll bar.

I attached it with 3M automotive moulding tape. Then I took measurements and rough cut a piece of the foam board.

Used a Sharpie pen to trace the contour of the roll bars and back deck.

And through trial and re-trial, I cut and sanded the foam board with a sanding wheel drill attachment.

Until I got the best shape possible and fit it in to place.

This is my template for the LEXAN which I only want to cut once.

I then traced it onto the lexan leaving the clear protection film on and lined it with masking tape to trace on and cut through.


Then used the same sanding wheel to shape, then smooth and polish the edges with smaller grit wheels.

Now slide it into place. To make a tight fit I cut a piece of black felt 1/8th inch thick. It pads and holds the lexan nice and tight and keeps it from moving.

For the etched logo I printed out a Z4 logo from the internet. This one -
http://www.cartype.com/pics/1618/full/bmw_z4_logo.jpg
Then traced it onto a piece of Clear shelf lining contact paper, centered it and stuck it down.

Then added a bottom edge trim to keep it from flexing and trimed the aluminum edging with self adhesive black auto trim.


All for around 25 dollars U.S.
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      10-02-2009, 09:46 AM   #2
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nice work, looks great
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      10-05-2009, 11:52 AM   #3
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very very nice! Definately a project i'll consider over the spring!
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      10-22-2009, 05:24 PM   #4
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can you sell? lol

I will buy it from you in a heartbeat
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      02-27-2010, 05:35 PM   #5
BruceJ
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Trim?

I found the acrylic, and aluminum u-channel at Lowes, what size trim did you use, ie 1/2"? and where did you pick it up? Thanks

Last edited by BruceJ; 02-27-2010 at 08:00 PM.
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      04-30-2010, 01:10 AM   #6
amgandhi
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Please sell it as a kit.. Lot of people would be willing to buy!!
I can pay $100 without thinking twice
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      05-12-2010, 11:05 AM   #7
Chris04Z4
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what did u use to cut the lexan??
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      05-12-2010, 11:26 AM   #8
inTgr8r
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Nice job.


here's the one I made when I had my M Roady (think I still have it somewhere)

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      05-12-2010, 06:22 PM   #9
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^that's a great job. Looks absolutely like OE and the black trim matches perfectly.

Nice looking units= both of them.
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      05-12-2010, 07:14 PM   #10
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Quote:
Originally Posted by Chris04Z4 View Post
what did u use to cut the lexan??
Lexan will cut with either a jigsaw or a band saw. In either case make sure to tape off the the entire surface to help prevent scratches later on. Here's mine. If you happen to scratch it up a porter cable 4215 and some Meguiars PlastiX polish will take out most scratches. Only clean with distilled water and microfiber. Frankly, for scratch resistance, acrylic will do a a better job than Lexan and is cheaper and more readily available(Lowes). Here's mine.
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Last edited by BruceJ; 05-12-2010 at 07:30 PM.
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      05-15-2010, 06:22 PM   #11
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Quick Question,

how do the aluminum trim pieces attach to the roll bars and the deck?

Thanks!
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      05-16-2010, 07:53 PM   #12
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Quote:
Originally Posted by 007miata View Post
Quick Question,

how do the aluminum trim pieces attach to the roll bars and the deck?

Thanks!
3M trim/moulding Tape - not the foam stuff - you can find it in most auto parts stores. Make sure you clean all surfaces with rubbing alcohol first.
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      05-27-2010, 08:04 PM   #13
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wow thats very skillfull of you! I wish you were selling them because I would absolutely buy it!
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      05-30-2010, 07:58 PM   #14
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Sorry, got a day job, and for the most part the wife and kid take up the rest. Really, if you dont have the time, skill or tools the one from Roadster solutions is pretty good. It may be hard to swallow the $270 pill, but once you put it on I think you would easily think its worth it. Especially in comparision the BMW 500 buck whiz bang screen.
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      10-26-2010, 11:47 AM   #15
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"3M trim/moulding Tape - not the foam stuff - you can find it in most auto parts stores"

Bruce, I haven't been able to find the 3M trim tape- except online at 3M, in 72 yard rolls. That's about 71 more yards than I need. If you have some left, could you send me a yard if I send you $5. ? Thanks, Ray Lynch
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      10-26-2010, 12:52 PM   #16
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Look for 3M mounting tape. Even Wal-Mart sells it around where I live.
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      10-30-2010, 12:54 AM   #17
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Roadster Solutions windscreen

Here is my Roadster Solutions windscreen. We just love it! No vibration or rattling. Well made product!
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      11-10-2010, 07:46 PM   #18
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Hi WamZ4. Awesome Job!! I'm planning on trying this tomorrow. I really appreciate you posting your process!

Two quick questions:

1. How did you achieve the even curve of the top?

2. How exactly did you notch the aluminum trim? (It looks like you just notched it on the bottom of the 'U' ...if so, did you go just deep enough to remove the bottom of the 'U', or did you go deeper than that?
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      11-13-2010, 03:52 PM   #19
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Quote:
Originally Posted by BruceJ View Post
Lexan will cut with either a jigsaw or a band saw. In either case make sure to tape off the the entire surface to help prevent scratches later on. Here's mine. If you happen to scratch it up a porter cable 4215 and some Meguiars PlastiX polish will take out most scratches. Only clean with distilled water and microfiber. Frankly, for scratch resistance, acrylic will do a a better job than Lexan and is cheaper and more readily available(Lowes). Here's mine.

I noticed you do not have anything between the pillars.... what if any affect does this have on wind? or is the single large wind blocker between the seats enough?
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      11-13-2010, 05:34 PM   #20
BruceJ
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Quote:
Originally Posted by bucko521 View Post
I noticed you do not have anything between the pillars.... what if any affect does this have on wind? or is the single large wind blocker between the seats enough?
Works well for me
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      02-17-2011, 03:58 PM   #21
WAMz4
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Quote:
Originally Posted by ag90fox View Post
Hi WamZ4. Awesome Job!! I'm planning on trying this tomorrow. I really appreciate you posting your process!

Two quick questions:

1. How did you achieve the even curve of the top?

2. How exactly did you notch the aluminum trim? (It looks like you just notched it on the bottom of the 'U' ...if so, did you go just deep enough to remove the bottom of the 'U', or did you go deeper than that?
Sorry, been gone awhile.
1 - the curve was done with 1/4 inch graph paper drawn on the foam board after cutting to fit the sides and bottom, then used graph paper to make sure the curve was even all the way across the top.

2 - The alluminum trim is 1/4 inch "U" trim from home depot, The notch is actually at the top of the U across both upright sides and cut all the way down to the bottom of the channel without going through it so it can spread while the flat back or bottom of the "U" is one long uncut strip that can bend to fit the curve of the roll bar.
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      02-17-2011, 04:53 PM   #22
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Has anyone tired both the lexan/acrylic wind blockers and the mesh ones? I read somewhere that BMW tested it and found that the mesh worked better as it evened out the cabin pressure. Then again visibility is way better with acrylic (and IMO looks slightly better, you guys did an amazing job!). I'm also considering rolling my own.
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