Hailcage V1.00

[NealRasmussen]

Fairly done with my hailcage. Might add side protection for spring...

A front and back screen fold up to the roof via eye-bolts.





They fold down over the windows.



They attach to a 3/4" PVC frame U-bolted to the luggage rack.

Cost is about $60-70. Cheaper if you have any scrap or junk yard near.
PVC pipe and 1" square rabbit fence. Suction cup feet for the front.

If you do it with PVC, lay it out completely before glueing joints. This will save you some "doh!"s.

A heavy gauge wire was added to the front as a safety line. It goes around the hood hinge and up to the front shield. I think this will give me 5-10 seconds to make it over to the sholder before it comes off. A back safety line would not be a bad idea.

 

[NealRasmussen]

$ 2.50 *4 - 3/8" Eye-bolts
$10.00
$ 0.30 *8 - 1/2" Elbows
$ 2.40
$ 1.50*2 - 1/2" Cross
$ 3.00
$ 0.50*11 - 1/2" Tee
$ 6.50
$ 1.50*3 - 1/2"x10' pipe
$ 4.50
$13.00*2 - 1" Square mesh steel rabbit fence. 2' wide x 15'.
$26.00
$ 4.00*2 - Flat black spray paint - outdoor - UV
$ 8.00
$ 0.80*10' - Heavy gauge coated copper wire as safety lines.
$ 8.00
======
Make that $70. Find some wire mesh at the salvage yard, and that's 1/3 to 1/2 the cost! Darn Wabbits!

 

[Dan Robinson]

Looks good - You might be able to perma-deploy the front guard by propping it up with vertical supports. That way you have full-time protection without having to stop and get out to deploy, and no detriment to visibility.

Just put it through the paces on some rough back roads and rural roads at highway speed, that will reveal any weaknesses.

 

[ScottCurry]

I congratulate you for building this. It's very creative. There are a few safety items about your design you might want to test, if you haven't done so already.

• As Dan said, does the front shield obstruct your view? Maybe install it parallel to the roof. This would still provide the same protection, but without obstructing your view.
• Are those suction cups going to hold in a relative 100mph wind? For example, driving down the freeway at 80 mph in a 20 mph head wind. If not, consider a permanent install instead (with everything bolted to the car and no need to get out to deploy it).
  
• Are the zip-ties going to break when hail hits the rabbit fence? I bring this up because I saw another hail shield fail due to this. Maybe try hitting some baseballs into it to test it (not with it on the car; in case it fails).
• Anything else you can think of, such as it falling off and hitting another vehicle while driving down the road?

Again, I like your design and creativity to make it less obstructive while not in use. I'd love to see how your design holds up against some testing. And $70 for the whole thing!? That's amazing.

 

[Drew Terril]

Nice work Neal!

 

[NealRasmussen]

I've speed tested it to approx 100mph. This is 75mph on the HE Baily (85) into a 10-15 kt headwind. But the real test is going W of Calument on the two lane road and no sholder. Often into a SW wind of 30MPH but the killer are the semi trucks going E at 70-75 in a 65. I guess it would be in the range of 65mph hitting 60mph. My hood actually ripples.

I have heavy wire guides going from hood hinges through a strand of rabbit fence and around the front shield's pipe. Just in case. So it may well break, but I should have time to get over with the hazards on.

I hadn't thought of the horizontal kind. This has enough downforce the suction cups seem fine. I've done 60mph with it down. I've thought of backup latches, perhaps a modified gate latch. One on each side.

After the lotto winning soon, I will make the engine hood a two piece. Regular metal and then an acrylic overlay which can fold up over front windshield. Oh wait. If I won the lotto I'd just get a new car. nvm

Thanks for the zip tie head's up. Might replace with wire wraps... They're also sharper than sh...

 

[Dave Ragozzine]

Fairly done with my hailcage. Might add side protection for spring...

A front and back screen fold up to the roof via eye-bolts.
View attachment 9430
View attachment 9431
View attachment 9432
View attachment 9433

They fold down over the windows.
View attachment 9434
View attachment 9435

They attach to a 3/4" PVC frame U-bolted to the luggage rack.

Cost is about $60-70. Cheaper if you have any scrap or junk yard near.
PVC pipe and 1" square rabbit fence. Suction cup feet for the front.

If you do it with PVC, lay it out completely before glueing joints. This will save you some "doh!"s.

A heavy gauge wire was added to the front as a safety line. It goes around the hood hinge and up to the front shield. I think this will give me 5-10 seconds to make it over to the sholder before it comes off. A back safety line would not be a bad idea.

I'm making up plans for something similar but made of Lexan Polycarbonate. A 18x24" sheet of .093" thick Lexan is $20.58 at Home Depot. You can probably find larger sheets for cheaper on wholesale websites though. Oh and if you are going to make headlight or side mirror protectors, look for Bucket Grids in the painting isle. They are made of metal, square and are perfect for protecting lighting. They cost less than $5.00 a piece too.