Reducing Windnoise / Raingutter Fillers

First I made the A-pillar deflectors out of glassfiber reinforced resin, which worked quite good. But did have a home-made look to it (of course, that’s logical because it IS homemade.. 🙂 ) .  See this page on how I created them and how they looked. It worked quite well, and used it for a long time.
But then I discovered the proces called vacuum forming. In this proces, plastic is heated to a temperature to which it is flexible, and then it is pulled over a mold using vacuum. Look it up on YouTube, there lots of examples can be found.
With vacuum forming one can create nice thin plastic objects, perfecty shaped after a positive mold. This sounded perfect for creating A-pillar deflectors. The idea is to create an A-pillar deflector that can be pushed under the window rubber on one side (just like my rear window spoiler) and around the A-pillar edge on the other side.

For creating the mold, I purchased a front window frame cutout for a 1303 (super) beetle:

VW super beetle front window frame

 

I then cut out the A-pillars:

VW beetle A pillars

 

Then I filled the rain-gutter with fiber reinforced resin:

Creating the molds
(they are in a chest with a electric heater, I use it to let the fiberglas harden during winter temperatures)

 

Then put some filler on it to smooth it:
Smoothing the mold

And repeat the proces until you’re bored, en then repeat again.. ;-(

On the next page I will be using the molds for vacuum forming.

27 Comments

    • Hi Jürgen,

      I have sold a few sets, but not much. They are still a bit “experimental”, I create them out of thin plastic using my homemade vacuum former.
      They require work to get smooth too, it is not a nicely finished ready to use product.
      I don’t have any sets “in stock” currently. I sometimes create them when more people ask about it, and then I create a few sets in a batch.

      Greetings,
      Gerrelt.

      • Hi Gerrelt,
        my request is nearly 1 year ago. I am still interested (as Jeff Kritz :))
        How long is your mail list of interested guys?
        We are just in front of a new Season……
        All the best for 2017
        Jürgen

        • Hi Jürgen,

          I see what I can do… 🙂
          I hope I will produce some this year, preferabele before the season starts of course..

          Best wishes for 2017 to you too!

          Greetings,
          Gerrelt.

      • I have been trying for the longest to purchase a rear roof spoiler and a pair of reflectors from you without success. I’m reaching out again.

    • Hi Jeff,

      I can add your e-mail to a list, then I will inform you when I make new ones (but that take quite some time..).
      A set will cost around 30 euros.

      Greetings,
      Gerrelt.

    • Hi Khalid,

      OK, I will add you to the list.
      Yes, they will allow water to pass underneath. They are hollow, and there is a hole at the top and the bottom.

      Greetings,
      Gerrelt.

  1. I would also be interested in a set of these. I already have one of your rear window spoilers. Thanks.

    • Hi Rick,

      I will add you to the list (and make a mental note to start making a batch again…).

      Greetings,
      Gerrelt.

  2. Hej Gerrelt,
    here is one more to put on your list for gutter fillers. After traveling Germany north to south and back in my VW 1303 Bubster, I feel that I am in need for some aerodynamic upgrades. Wind noise is quite bad when cruising at 160-180km/h.

    Greetings from Sweden,
    Olaf

    • Hi Olaf,

      I just spent an hour or so going through the excellent build thread of your Boxer Beetle. Wat a brilliant build, very nice!
      Very cool car.

      I will add you to the list, and try to make some time soon to make a batch….

      Greetings,
      Gerrelt.

  3. I’d be interested ina pair of these gutter fillers and a rear window spoiler also. Can you get in touch if you have any for sale currently?
    Thanks
    J

    • Hi James,

      I am currently producing a new batch, but they will probably all be spoken for.
      Shall I put you on the list?

      Greetings,
      Gerrelt.

      • Hi, yes that would be good, but it also depends on the price including the roof spoiler.
        Maybe you could email me?
        Thanks!

  4. Gerrelt, very cool stuff you are doing.
    I am interested in the rain gutters and rear window spoiler for ’74 Super.
    – Craig

  5. Hi Gerrelt
    I’m also interested in a set of rain gutters and a roof spoiler. Do you still sell them?

    Best regards from Germany
    Mig

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