Top Stories  
 
Roush News
About Roush
Readers Album
FnSweet Garage
Misc Stuff
 
FnSweet Forum
 
FnSweet Links
Events Calendar
FnSweet Store
Roush Registry
 

 
Join FnSweet!
 
Site Sponsors
Sponsor Us
Contact Us
 
 

How-I-Did-It: Soft Tonneau and Windguard Install
Posted April 4, '02

 

Soft Tonneau and Windguard Install for 1999+ Mustang

Here are the steps I took to install the soft tonneau and Windguard on my '01 Mustang convertible. The kit was purchased from Haney Motorsport for ~$400. The kit comes complete, as I did not need to purchase anything to fully install the kit.

The kit came with complete instructions. The Windguard instructions are printed from the Haney Motorsport site. You can reference them there for larger pics. The soft tonneau did not come with very good instructions, but they were not very necessary. It is very easy to install.

This articles shows the steps that I did to complete the install. As with all procedures, consult the manufacturer's instructions first. This is only How-I-Did-It.

 

The Kit:

The Windguard and soft tonneau come in two seperate boxes. The Windguard box had a piece of plastic taped to the outside that I did not use. It is optional. The kit contains the Windguard, hardware, and bar for the tonneau, as well as a set of instructions. The box for the soft tonneau included the tonneau and a bag of snaps.

 

Preparation:

Workspace: A well lit area with the top down on the car.
Tools and Supplies: Allen wrenches supplied with the kit, phillips screwdriver for snaps, power drill with 5/16" bit, alcohol and steel wool/abrasive pad, rule.
Left-over Parts: Plastic part taped to Windguard box, screws removed from rear trim piece.

Quick Instructions:

  1. Clean lightbar with alcohol
  2. Apply temporary guides
  3. Measure for holes, drill holes
  4. Install metal inserts
  5. Install Windguard
  6. Apply rubber seals
  7. Install snaps in rear trim piece
  8. Install soft tonneau
  9. Place tonneau bar in place
  10. Tighten everything up

Procedure:
Note:
Some full-sized images have additional information, arrows, etc.

(Click thumbnail for full-sized image)

Getting Started
The underside of the lightbar needs to be cleaned before application of the rubber strips. Oils and gunk will prevent the rubber strips from getting the best grip possible. The rubber strips are used to hold the Windguard in place.

The instructions call for using a steel wool pad and rubbing alcohol. I did not have steel wool, so I used a Scotchbrite pad and a towel. You only need to concern yourself with the area in front of the plastic strip under the lightbar (towards the windshield).

 

 

 


Apply the Temporary Guides
There are two small foam pads included in the kit. Apply these to the front of the plastic strip on the lightbar, in the 10 o'clock and 2 o'clock positions on the lightbar. Figure the center is 12 o'clock, and the two ends are 9 & 3 o'clock.

Be sure to stick these pads only once. I decided to move the pads after they were stuck (I positioned them too high), and they lost a lot of their stickiness. They need to be firmly planted to hold the Windguard in place while measuring.


Measuring and Drilling Holes in the Lightbar
This step would be easier if you have someone to help out. With a measuring tape, find the center of the lightbar and mark. Next, hold the Windguard up to the lightbar, resting it on the temporary guides. Center the Windguard using the handle on the Windguard as the middle point.

When the Windguard is centered, position the L-brackets so that the are ~ 1/2" from the forward part of the lightbar. Once the brackets are even on both sides, mark gently with a pencil. Measure from the edge of the lightbar to the mark to assure they are equal distance from the edge.

Once the marks are correct, measure one more time - you will be drilling a hole in your lightbar soon. Make sure you only have to drill once!!

The instructions call for the holes to be drilled using a 5/16" bit, and to go 3/4" deep. I used black tape to mark on the drill bit 3/4". When drilling, be sure that the drill is perpendicular to the lightbar. It is very easy to drill into the lightbar, so a lot of force is not needed. Also do not elongate the holes while drilling!


Install the Metal Inserts Into the Lightbar
Once the holes are drilled, clean up the shavings and blow out the holes in the lightbar. Place an insert into the hole. You may need to tap slightly on the insert to get it started. Use the included allen wrench to seat the insert fully. Do not over torque.


Install the Windguard
Place the Windguard under the lightbar, with the back of the Windguard resting against the temporary foam pieces. Install the thumbscrews through the L-bracket and into the newly installed metal insert in lightbar. Snug up by hand.


Apply the Rubber Seals
With the Windguard in place, it is time to install the rubber seals. Start with the front seal and remove a small amount of the orange plastic. Position the seal slightly above one of the L-brackets and slowly apply to the lightbar. Remove the orange plastic as you need more sticky stuff. Keep the rubber seal snug against the Windguard and press firmly against the lightbar. Do not press too much against the Windguard, as you don't want to distort the temporary foam guides on the back side.
Once you have worked your way to the opposite side, there will be a bit of rubber left over. Trim with a kife.

Repeat the process for the back side of the window. When you get to the first temporary foam piece, remove it and use some alcohol to remove any gook left from it. Continue along the Windguard and lightbar in the same manner as the front seal. Remove the second temporary foam piece and clean. Be sure to allow the alcohol to dry before continuing.Once you reach the other side, you may not have to trim the rubber.

When the rubber seal is in place, remove the Windguard. Go along the rubber seal and press firmly to seat them. Re-install the Windguard and the installation of the Windguard is complete!

 

 


Install Snaps in Rear Trim Piece
To install the soft tonneau, open the trunk to access the screws in the rear trim piece. Remove a screw and replace it with a supplied screw/snap. There will be 6 of these to do. The screws that are removed will not be reused.


Install Soft Tonneau
Unfold the tonneau and lay it out on the back part of the car. It is best if you let it sit out in the sun before doing this process to warm up the material. Slide the rear part of the tonneau into the opening between the open trunk lid and the rear trim piece. Snap the tonneau to the newly installed snaps on the trim piece.

To install the sides, slip the plastic flaps on the tonneau under the trim piece. Completely tuck one side, then go to the next. There are also metal clips that connect to the slot where the seatbelt comes out. I did not connect these clips.

Once the tonneau has sat in the sun a bit to warm up, you can slide the top around to even it out.

 


Place Tonneau Bar in Place
The tonneau bar is a cross-bar that sits on top of the thumb screws for the Windguard. The tonneau fits under the Windguard and over the top of the cross-bar. The tonneau then hangs below the bar. Placed the bar under the part of the tonneau that is hanging down, install the flat end of the bar over the a thumb screw. Lift up on the bar and place over the other thumb screw. There is a notch in the bar - place that over the thumb screw and rotate into position.

I had to trim a small amount off of the bar for it to fit as I wanted it to. To do this, I used a Dremel Tool (could have easily used a hacksaw) to cut off the straight end of the bar. I then rounded the edges and applied some black tape to finish it off.

 


Tighten Everything Up
To finish the job, make sure the thumb screws are tight, and the tonneau is centered and stretched as well as possible. If the L-bracket in the Windguard loosens up at all, there is a supplied allen wrench to tighten it. The L-bracket attaches to the Windguard using a rubber compression nut and a small allen head screw.

As a final touch, be sure to apply an "fnsweet.com" sticker to the Windguard!!

 


A few pics of the final product


Its Done!

This was a pretty simple installation. The most difficult part was measuring for the holes to be drilled. If I would have had a second set of hands, it would have been helpful. This install is very possible with one person though.

I give this product high marks. I have taken the car out on the freeway several times and the difference in the wind is remarkable. At cruising speeds, windows down, you can easily carry on a conversation with you passenger. It does a great job doing what it is supposed to do.

The fit of the tonneau is good. There are slight puckers in the rear when it is first installed, but as the material warms up, it is easy to slide the top around into position. The puckers are now barely noticeable. The part of the tonneau that hangs down does not flap around, and the tonneau itself does not move a whole lot while driving.

I typically drive with my seat move as far back as possible. With the Windguard/tonneau combination, I am still able to have my seat moved fully back, but I had to "decline" the seat by one or two clicks. So, I am sitting in more of an upright postion now. This was done because I did not want the seat actually resting on the bar.

The Windguard was designed and built by Pat Haney of Haney Motorsports, and the tonneau is a Ford product. The kit is available from the above web site.

See you with the top down!

}}kev

 

6692 Visitors

 

 
 
   
 
 

 
SEMA Member
 
 

This publication is not affiliated with Roush Performance. All trademarks referenced in this site are the property of their prospective owners.