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Old 02-08-2012, 11:02 AM
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Default DIY rack fairing?

I have a new Gamiviti Expo rack on my rig and I'd like to make a wind fairing for it instead of just buying one. The problem I'm having is finding a piece of plexiglass or lexan that is at least 50" long.

Home Depot sells 4'x3' (almost long enough) sheets for $80 but for that price, I can just buy the 50" Yakima one. Buying would be easier, but I'd like to make one if I can find the plexiglass in the right size. At least 50"x12" is what I'm looking for.

Any ideas?

Fish
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Old 02-08-2012, 11:06 AM
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I have used these folks in the past for plastics. They can cut whatever you need. I usually get a rectangle of close to the right size then finish it with a jig saw.

Every 4th friday they have a remnant sale too....

http://www.coloradoplastics.com/
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Old 02-08-2012, 11:15 AM
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Another is Plasticare, closer to us on the southside.

http://www.plasticareinc.com/

Also check Craigslist, there's usually Yakima and Thule fairings that go for about $30 typically.
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Old 02-08-2012, 02:13 PM
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Stan I'd pick up a used fairing off CL.. you'd be hard pressed to DIY for under $50 when you factor in the mounting hardware. Even if you get a smaller one today, if you decide you want a bigger one later you could recycle all the mounts, and just swap out the plastic part with a larger piece of plastic. But the small one may be enough to knock down the wind noise anyway.

And to make all the Yakima stuff work, try a 1" section of sprinkler tubing, split lengthwise. Then snap the tubing over the bar, which quickly turns the 1" bar into a 1.125" bar.
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Old 02-08-2012, 07:26 PM
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I found exactly what I was looking for at Plastic Care Inc. Thanks Dave!
Picking up a piece of of 55x12 plexiglass tomorrow for $23. Hoping I can just cut it to shape with a Dremel Tool. Now I just have to fab some brackets....
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Old 02-08-2012, 08:03 PM
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I usually go to Regal Plastics. Great prices and they are easy to work with.

I have made a few fairings but I use 1/4" ABS. I have had them on vehicles for 10 years or more with zero issues. still they clean up and look as good as the day I made them.

ABS is usually black, cuts great without chipping, sands great to soften the edges, flexes well to get a curve, has a textured side and a smooth side (I use the texture side out) and it's durable as anything.
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Old 02-08-2012, 08:52 PM
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Quote:
Originally Posted by Gerdo View Post
I usually go to Regal Plastics. Great prices and they are easy to work with.

I have made a few fairings but I use 1/4" ABS. I have had them on vehicles for 10 years or more with zero issues. still they clean up and look as good as the day I made them.

ABS is usually black, cuts great without chipping, sands great to soften the edges, flexes well to get a curve, has a textured side and a smooth side (I use the texture side out) and it's durable as anything.
I'll take a look at that tomorrow too. Thanks.
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Old 02-08-2012, 09:50 PM
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Quote:
Originally Posted by DaveInDenver View Post
Another is Plasticare, closer to us on the southside.

http://www.plasticareinc.com/

Also check Craigslist, there's usually Yakima and Thule fairings that go for about $30 typically.
X2 they are good people.
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Old 02-09-2012, 08:04 AM
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you could do my favorite - an 80 running board cover cut to size.
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Old 02-09-2012, 08:10 AM
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Quote:
Originally Posted by Fishy View Post
I found exactly what I was looking for at Plastic Care Inc. Thanks Dave!
Picking up a piece of of 55x12 plexiglass tomorrow for $23. Hoping I can just cut it to shape with a Dremel Tool. Now I just have to fab some brackets....
Plexiglass as in Acrylic? That won't hold up too well. The UV will yellow it, it will develop lots of small micro cracks which lead to a big crack. Lexan (polycarbonate) would hold up better is you want something clear. Black ABS would be the best.
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