Hail Shield Build Help

[Dan Robinson]

I would still like to figure out a good, sleek "field deployable" all-windows guard design that is also as low-profile as possible. Something that minimizes MPG drag and also doesn't look ridiculous. Front guards really get in the way of photography and dashcam videos, and unless it lowers, won't protect the lower part of the windshield when the vehicle is in motion. Right now my side guards require exiting the vehicle to deploy, which is a problem when larger hail begins suddenly and you can't get out of the car.

Thinking of something flat on the rooftop where all guards slide out horizontally to deploy, the side guards then pivoting down and locking into place.

 

[Jordan Doane]

I would still like to figure out a good, sleek "field deployable" all-windows guard design that is also as low-profile as possible. Something that minimizes MPG drag and also doesn't look ridiculous. Front guards really get in the way of photography and dashcam videos, and unless it lowers, won't protect the lower part of the windshield when the vehicle is in motion. Right now my side guards require exiting the vehicle to deploy, which is a problem when larger hail begins suddenly and you can't get out of the car.

Thinking of something flat on the rooftop where all guards slide out horizontally to deploy, the side guards then pivoting down and locking into place.

In the future I’ll just do 3m security film!

 

[Joe Cameron]

In the future I’ll just do 3m security film!

Even for front windshield and rear window ???

 

[Marc R. O'Leary]

Dan Shaw runs 3m film but he still got wrecked by gorilla hail this year. I think it's better served as a reinforcement to something more sturdy like a proper cage.

I design things for a living, but never bothered with building a cage. I tend to steer clear of hail whenever possible. I did install a light bar and designed a cutoff fairing. Also designed a skid pan which helped a ton when bombing down dirt roads at 70mph.

For a base rack though, look at Rola. I bought a 6ft rack for my subaru for under $200. It's sitting here in the garage since I haven't decided if I want to put it on the Sorento...mostly from a mpg perspective. Going camping tomorrow and kinda wish I had it up there, but no cross bars came with my car and they cost more than the rack did.

 

[Dan Robinson]

Reviving an old thread with some updates to this topic. I have retired my wire-shelving-based shields and am currently installing a rig using galvanized hardware cloth (a type of wire fencing you can get at any home improvement store). It is very strong and very lightweight. I’ll post pictures soon.

I used this material as the rear window guard on my last vehicle. This was necessary because the rear liftgate required the guards to be fully cantilevered out from the roof rack in order to allow the liftgate to open. The shelving panels were just too heavy to safely do that configuration. The material took a solid softball strike during the May 29, 2022 Taylor, Nebraska supercell, saving the rear window. The material held up just fine- dented, but not significantly. It is more than sufficient to rely on for this application.

So, I am redoing the entire rig with this material. The main benefits are that 1, its light weight means less structural support is required and 2, it has far less wind resistance than the shelving panels. That means it is not only much quieter, it takes far less of a toll on fuel economy. The shelving panels produced a shrill cacophony of whistling at highway speeds, and when driving into a significant headwind, cut gas mileage in half.

I’m reusing parts of the original rig’s frame rails for this new one. It attaches to the car’s roof rack mounting holes using 8mm bolts.

I had hoped to have it finished before today’s chase, but storms fired 3 hours earlier than expected. When it’s completed I’ll make another update.

 

[Dan Robinson]

The basic build of shield rig 2.0 is finished. Yet to do is the fold-down side guards. A couple of quick photos while sitting at today's target:

1.) The dent in the rear guard from the 5/29/22 softball. I've been using this rear guard section with my old rig since 2021. I could have bent the dent back into shape, but left it as a battle scar.

2,3: Shots of the liftgate cantilever and rollers, with the liftgate closed and open. I used soft rubber casters that don't damage the car's paint.

4.) Shot of the galvanized hardware cloth material on the side and front guards, with part of the frame. The light weight of the material means lighter aluminum frame pieces could be used, as well as using primarily zip ties instead of 1/4" bolts that were needed with the shelving panels.

Will post more when I have the fold-down side guards done.

 

[Shawn Camp]

on this issue.......I will have more later to say.............. . think Metal Supermarket........



Shawn C.

 

[Dan Robinson]

I had an inadvertent “extreme” stress test of my new rig yesterday after I hit a turkey in northern MIssouri. The failure point was on both of the main frame rails at the forward roof rack attachment studs. The main rails bent, but did not break. There was one small stress fracture emanating from the bolt hole on the underside of one rail. There were no failures or deformation in the hardware cloth, bolts/fender washers or zip ties. No damage to the car roof or rack mounts, the main rail deformation absorbed the rack’s impact forces. A validation of the durability of the material and components!

I will only need two new main frame rails (and a new windshield), the old ones are no longer safe to use.