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Old 10-07-2011, 07:43 AM   #11 (permalink)
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My expectations for a measurable gain were low, but this tip:

"Lexan/plastic covers over "bucket" style headlights"

had given me some hope for a little gain at high speeds.

Hmmm...Maybe I'll reevaluate this. The biggest draw to the covers is keeping the lights snow-free; maybe that's good enough.

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Old 10-07-2011, 01:44 PM   #12 (permalink)
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Use Harbor Freight heat gun--cheaper.

Use tape for prototype.

Use PETG instead of polycarbonate--cheaper, almost as strong, weatherproof.

You may get marginal aero improvements, but given the gross overall shape of the vehicle going in, don't expect much.
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Old 10-07-2011, 02:23 PM   #13 (permalink)
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I built the fog light covers after driving in a heavy snowfall that filled the fog light openings and made the fogs unuseable. The covers are a noticeable improvement in that respect.

Aerodynamics of the covers? Don't know, don't really care. Should be some drag reduction from stopping airflow around the fog lights, but don't need the covers for that.

I used acrylic. Have fun cutting that stuff - it's brittle and wants to shatter. Try clamping between two sheets of plywood when cutting. Polycarbonate is much easier to cut, but the local hardware store had acrylic in stock.
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Old 10-07-2011, 05:43 PM   #14 (permalink)
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Oh... if snow filled buckets is the problem and it bothers you enough, perhaps cutting the bucket away and/or relocating the lights flush is an option. Covers tend to get filthy on the backsides.
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Old 10-07-2011, 08:55 PM   #15 (permalink)
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When I first installed them, they filled up with dirt from behind. So I removed the covers, foamed the gaps around the fog lights, and reinstalled the covers. The back sides have stayed clean since.

Relocating the lights flush is WAY too much work.

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