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Old 05-14-2008, 12:49 AM   #18 (permalink)
Otto
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To me, noise reduction alone would seem to make this a worthwhile experiment.

The screen, in addition to making smoother airflow under the car and less noise in the first place, probably also reflects and absorbs noise by acting as an acoustic barrier of sorts. A smoother screen with better acoustic absorption would probably work even better.

Your aluminum windowscreen fabric is a great idea, and the price is right. To make it super-smooth after fitting it to the car, you could then use a flat table covered by smooth glass or plexiglass: Pour plastic resin such as polyester on the flat table and spread it evenly. While the resin is still fluid and before it sets up, secure the pre-fitted aluminum screen to the table, such that the resin penetrates and forms a matrix with the screen fabric. (A vacuum bag would help lots with this.) Once the resin hardens, peel the matrix off the table, and the hardened but flexible resin will retain the smooth texture imparted by the table top. Put the pre-fitted screen back on the vehicle for a super-smooth finish.
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