Hi Guys,
Thanks for your comments so far!
I had a go at making the grill block I pictured in post #14, I tried to use the same materials as the wind deflectors, but I found that that material would accept a bend across one plane, but when I tried to bend it across another plane it cracked (is it 'plane' or 'plain'...?)
So back to my materials research...
Also looking at some of the feedback on the wind deflectors, especially #16 from euromodder, there may be a question as to whether they are simply trapping air and pushing them onto the rotating tyre itself...?
So there could be a much smaller/simpler/lighter version in the pipeline...
On the plus side, all the holes I'm drilling in my front bumper will soon be adding up to a serious weight loss...