Not a fan of that piece at all but great call out.We sometimes get that weird popping noise as well from the passenger side. It's weird but I'm almost thinking it's the little Bestop logo.
I have put the pipe insulation on the cross bar which stops the flapping noise but I think that weird popping noise may be that logo catching the wind just right.
Did you tighten that velcro piece as much as possible after adding the filler?
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