Ultimate 10-step wind noise fix for the Bronco Sunrider Top

[horseplay]

These are the 10 step-by-step fixes I found to be most effective in reducing Sunrider for Hardtop wind noise. Although my rig is a 2-door, these methods also apply to the 4-door. Some of these are old news and appear in previous threads which are duly credited. Other solutions were developed after some creative tinkering. Together these minor, inexpensive modifications made a tremendous difference in squelching interior wind noise. I provided links to the supplies I used. Altogether I spent less than 30 bucks and an hour of work time.

Supplies:

1/4" x 5/16" D-section weatherstrip (https://a.co/d/eM1QD0v)

2" x 1" air conditioning foam (https://a.co/d/dpuvegQ)


6' foam pipe insulation tube (https://www.homedepot.com/s/3/4 inch pipe foam insulation?NCNI-5)

rubber end caps (https://a.co/d/12Uvby2)

silicone lubricant (KEZE Silicone Grease Automotive...)

STEP 1. As you can see in the photo. a postcard-sized sheet can slide through the side mounting mechanism of the Sunrider which means that outside air can enter here.

To seal the slight gap, open the top and remove the mounting bolts. Install 2" x 1" air conditioning foam (https://a.co/d/dpuvegQ) along the bottom of both gutters that run over the side windows (no adhesion needed).

STEP 2. To increase pressure from the Sunrider header on the secondary gasket at the windshield, add a double strip 1/4" x 5/16" D-section weatherstrip (https://a.co/d/eM1QD0v) across the Sunrider header (red arrows). LCW, another Bronco6G member, posted his solution: https://www.bronco6g.com/forum/threads/bestop-sunrider-wind-noise.33040/page-7. Be sure to clean the header area with isopropyl alcohol to assure adhesion. Also place a double strip (approx 3 3/4") at the very top edges of both sides of the header between the ridges on the roof material and the edges of the top (blue circle).

STEP 3. Install a single strip of 1/4" x 5/16" D-section weatherstrip (https://a.co/d/eM1QD0v) over the top of the Sunrider side mechanism from just under the back folding material to the front windshield gasket. This will further block wind entering under the side of the top. Be sure to thoroughly clean the surfaces with isopropyl alcohol to ensure proper adhesion.

STEP 4. Remove the plastic washers on both rear mounting bolts to eliminate the gap between the top and the rear of the Sunrider before retightening the bolts. This will allow the back of the top to compress against the roof seal. If appropriate for your situation, you can replace the 5.5mm plastic washers with 2mm thick ones (https://a.co/d/2V82Ra2) or thinner stainless fender washers.

STEP 5. Loosen the rear mounting bolts on both sides (red arrows) and loosen the center bracket bolts (green arrows), then tap the assembly rearward as much as possible with a rubber mallet (blue arrows) before retightening all the bolts. Sean Gloff posted the following instructions: https://www.bronco6g.com/forum/threads/bestop-sunrider-wind-noise.33040/page-2

STEP 6. Loosen the four front striker bolts (two on each side) at the front of the headliner (red arrows). Tap the strikers forward towards the windshield with a rubber mallet as much as possible (blue arrow) before retightening the four bolts. This will help pull the top down a bit tighter when latched. Again, thank you Sean Gloff: https://www.bronco6g.com/forum/threads/bestop-sunrider-wind-noise.33040/page-2

STEP 7. Flapping on the center cross bar can be fixed by opening the velcro and inserting a 1" wide x approximately 3' 2" long strip cut lengthwise from a 6' foam pipe insulation tube. (https://www.homedepot.com/s/3/4 inch pipe foam insulation?NCNI-5). Do not use any of the self adhesive surface to avoid a sticky mess during hot weather. Close the velcro material tightly against the crossbar and foam insulation.

STEP 8. The rivets used in the front brackets are too long, hitting and scratching the door header sheet metal. This could also affect optimal alignment of the top. File down the tips, clean the edges and place rubber end caps on both of the shortened rivet ends to avoid scraping. (https://a.co/d/12Uvby2). You will need to trim the length of the rubber tips for a snug fit.

STEP 9. Correct a leaky side window maladjustment with this simple procedure:


STEP 10. Thoroughly clean with isopropyl alcohol then rub silicone lubricant on all surfaces of the rubber molding along the whole length and width of the side windows and along the windshield header weatherstipping to soften the gaskets and provide a better seal. (KEZE Silicone Grease Automotive...)

This entire process really doesn't take all that much effort and it significantly reduces interior wind noise - at least for me. I hope you find this useful for your ride!

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[Amcole1984]

I've had my sunrider for over 3 years and I don't even notice the noise. Not saying there isn't any. I just don't even notice it. You get acclimated to it after a while.

 

[bkanar34]

These are the 10 step-by-step fixes I found to be most effective in reducing Sunrider for Hardtop wind noise. Although my rig is a 2-door, these methods also apply to the 4-door. Some of these are old news and appear in previous threads which are duly credited. Other solutions were developed after some creative tinkering. Together these minor, inexpensive modifications made a tremendous difference in squelching interior wind noise. I provided links to the supplies I used. Altogether I spent less than 30 bucks and an hour of work time.

Supplies:

1/4" x 5/16" D-section weatherstrip (https://a.co/d/eM1QD0v)

2" x 1" air conditioning foam (https://a.co/d/dpuvegQ)


6' foam pipe insulation tube (https://www.homedepot.com/s/3/4 inch pipe foam insulation?NCNI-5)

rubber end caps (https://a.co/d/12Uvby2)

silicone lubricant (KEZE Silicone Grease Automotive...)

STEP 1. As you can see in the photo. a postcard-sized sheet can slide through the side mounting mechanism of the Sunrider which means that outside air can enter here.

To seal the slight gap, open the top and remove the mounting bolts. Install 2" x 1" air conditioning foam (https://a.co/d/dpuvegQ) along the bottom of both gutters that run over the side windows (no adhesion needed).

STEP 2. To increase pressure from the Sunrider header on the secondary gasket at the windshield, add a double strip 1/4" x 5/16" D-section weatherstrip (https://a.co/d/eM1QD0v) across the Sunrider header (red arrows). LCW, another Bronco6G member, posted his solution: https://www.bronco6g.com/forum/threads/bestop-sunrider-wind-noise.33040/page-7. Be sure to clean the header area with isopropyl alcohol to assure adhesion. Also place a double strip (approx 3 3/4") at the very top edges of both sides of the header between the ridges on the roof material and the edges of the top (blue circle).

STEP 3. Install a single strip of 1/4" x 5/16" D-section weatherstrip (https://a.co/d/eM1QD0v) over the top of the Sunrider side mechanism from just under the back folding material to the front windshield gasket. This will further block wind entering under the side of the top. Be sure to thoroughly clean the surfaces with isopropyl alcohol to ensure proper adhesion.

STEP 4. Remove the plastic washers on both rear mounting bolts to eliminate the gap between the top and the rear of the Sunrider before retightening the bolts. This will allow the back of the top to compress against the roof seal. If appropriate for your situation, you can replace the 5.5mm plastic washers with 2mm thick ones (https://a.co/d/2V82Ra2) or thinner stainless fender washers.

STEP 5. Loosen the rear mounting bolts on both sides (red arrows) and loosen the center bracket bolts (green arrows), then tap the assembly rearward as much as possible with a rubber mallet (blue arrows) before retightening all the bolts. Sean Gloff posted the following instructions: https://www.bronco6g.com/forum/threads/bestop-sunrider-wind-noise.33040/page-2

STEP 6. Loosen the four front striker bolts (two on each side) at the front of the headliner (red arrows). Tap the strikers forward towards the windshield with a rubber mallet as much as possible (blue arrow) before retightening the four bolts. This will help pull the top down a bit tighter when latched. Again, thank you Sean Gloff: https://www.bronco6g.com/forum/threads/bestop-sunrider-wind-noise.33040/page-2

STEP 7. Flapping on the center cross bar can be fixed by opening the velcro and inserting a 1" wide x approximately 3' 2" long strip cut lengthwise from a 6' foam pipe insulation tube. (https://www.homedepot.com/s/3/4 inch pipe foam insulation?NCNI-5). Do not use any of the self adhesive surface to avoid a sticky mess during hot weather. Close the velcro material tightly against the crossbar and foam insulation.

STEP 8. The rivets used in the front brackets are too long, hitting and scratching the door header sheet metal. This could also affect optimal alignment of the top. File down the tips, clean the edges and place rubber end caps on both of the shortened rivet ends to avoid scraping. (https://a.co/d/12Uvby2). You will need to trim the length of the rubber tips for a snug fit.

STEP 9. Correct a leaky side window maladjustment with this simple procedure:


STEP 10. Thoroughly clean with isopropyl alcohol then rub silicone lubricant on all surfaces of the rubber molding along the whole length and width of the side windows and along the windshield header weatherstipping to soften the gaskets and provide a better seal. (KEZE Silicone Grease Automotive...)

This entire process really doesn't take all that much effort and it significantly reduces interior wind noise - at least for me. I hope you find this useful for your ride!

 

[bkanar34]

That’s a lot of mods. But based on experience, all needed to quiet the noise. I’m fairly opinionated as I had two sets of Sunrider tops for two different jeeps. The tops worked perfect and were super quiet. I did not have the same experience for the Bronco. Maybe in due time they will make the necessary mods, to improve upon the fit with your suggestions and others as well. The suggestions are super helpful!

 

[gwp]

These are the 10 step-by-step fixes I found to be most effective in reducing Sunrider for Hardtop wind noise. Although my rig is a 2-door, these methods also apply to the 4-door. Some of these are old news and appear in previous threads which are duly credited. Other solutions were developed after some creative tinkering. Together these minor, inexpensive modifications made a tremendous difference in squelching interior wind noise. I provided links to the supplies I used. Altogether I spent less than 30 bucks and an hour of work time.

Supplies:

1/4" x 5/16" D-section weatherstrip (https://a.co/d/eM1QD0v)

2" x 1" air conditioning foam (https://a.co/d/dpuvegQ)


6' foam pipe insulation tube (https://www.homedepot.com/s/3/4 inch pipe foam insulation?NCNI-5)

rubber end caps (https://a.co/d/12Uvby2)

silicone lubricant (KEZE Silicone Grease Automotive...)

STEP 1. As you can see in the photo. a postcard-sized sheet can slide through the side mounting mechanism of the Sunrider which means that outside air can enter here.

To seal the slight gap, open the top and remove the mounting bolts. Install 2" x 1" air conditioning foam (https://a.co/d/dpuvegQ) along the bottom of both gutters that run over the side windows (no adhesion needed).

STEP 2. To increase pressure from the Sunrider header on the secondary gasket at the windshield, add a double strip 1/4" x 5/16" D-section weatherstrip (https://a.co/d/eM1QD0v) across the Sunrider header (red arrows). LCW, another Bronco6G member, posted his solution: https://www.bronco6g.com/forum/threads/bestop-sunrider-wind-noise.33040/page-7. Be sure to clean the header area with isopropyl alcohol to assure adhesion. Also place a double strip (approx 3 3/4") at the very top edges of both sides of the header between the ridges on the roof material and the edges of the top (blue circle).

STEP 3. Install a single strip of 1/4" x 5/16" D-section weatherstrip (https://a.co/d/eM1QD0v) over the top of the Sunrider side mechanism from just under the back folding material to the front windshield gasket. This will further block wind entering under the side of the top. Be sure to thoroughly clean the surfaces with isopropyl alcohol to ensure proper adhesion.

STEP 4. Remove the plastic washers on both rear mounting bolts to eliminate the gap between the top and the rear of the Sunrider before retightening the bolts. This will allow the back of the top to compress against the roof seal. If appropriate for your situation, you can replace the 5.5mm plastic washers with 2mm thick ones (https://a.co/d/2V82Ra2) or thinner stainless fender washers.

STEP 5. Loosen the rear mounting bolts on both sides (red arrows) and loosen the center bracket bolts (green arrows), then tap the assembly rearward as much as possible with a rubber mallet (blue arrows) before retightening all the bolts. Sean Gloff posted the following instructions: https://www.bronco6g.com/forum/threads/bestop-sunrider-wind-noise.33040/page-2

STEP 6. Loosen the four front striker bolts (two on each side) at the front of the headliner (red arrows). Tap the strikers forward towards the windshield with a rubber mallet as much as possible (blue arrow) before retightening the four bolts. This will help pull the top down a bit tighter when latched. Again, thank you Sean Gloff: https://www.bronco6g.com/forum/threads/bestop-sunrider-wind-noise.33040/page-2

STEP 7. Flapping on the center cross bar can be fixed by opening the velcro and inserting a 1" wide x approximately 3' 2" long strip cut lengthwise from a 6' foam pipe insulation tube. (https://www.homedepot.com/s/3/4 inch pipe foam insulation?NCNI-5). Do not use any of the self adhesive surface to avoid a sticky mess during hot weather. Close the velcro material tightly against the crossbar and foam insulation.

STEP 8. The rivets used in the front brackets are too long, hitting and scratching the door header sheet metal. This could also affect optimal alignment of the top. File down the tips, clean the edges and place rubber end caps on both of the shortened rivet ends to avoid scraping. (https://a.co/d/12Uvby2). You will need to trim the length of the rubber tips for a snug fit.

STEP 9. Correct a leaky side window maladjustment with this simple procedure:


STEP 10. Thoroughly clean with isopropyl alcohol then rub silicone lubricant on all surfaces of the rubber molding along the whole length and width of the side windows and along the windshield header weatherstipping to soften the gaskets and provide a better seal. (KEZE Silicone Grease Automotive...)

This entire process really doesn't take all that much effort and it significantly reduces interior wind noise - at least for me. I hope you find this useful for your ride!

My Sunrider is much quieter than the hardtop panels. I don’t want to change a thing, nor do I dare mess with anything that seems to work so well already,

 

[RedRider]

I've seen comments elsewhere stating that the brand tag on the outside of the passenger side was a source of noise. Have you had that issue?

 

[Zavala]

Really good write-up @horseplay thank you!

 

[horseplay]

I've seen comments elsewhere stating that the brand tag on the outside of the passenger side was a source of noise. Have you had that issue?

 

[horseplay]

Not me

 

[Bonnie & Clyde]

I bought my 2 door hard top with 34 miles on it. It now has 121 miles and the wind noise is getting worse! Thanks for the write up. I will follow suit to some degree.

 

[MTjockey]

I've seen comments elsewhere stating that the brand tag on the outside of the passenger side was a source of noise. Have you had that issue?

Definitely! Especially with any cross wind. I've been considering cutting it off.

 

[LouBinWNC]

Definitely! Especially with any cross wind. I've been considering cutting it off.

I have this... Especially in cross winds !! I sent video to Bestop and they said it is within design specs.
I asked if I could cut it and they said that would void my warranty.

other than that noise is not all that bad.

 

[gwp]

These are the 10 step-by-step fixes I found to be most effective in reducing Sunrider for Hardtop wind noise. Although my rig is a 2-door, these methods also apply to the 4-door. Some of these are old news and appear in previous threads which are duly credited. Other solutions were developed after some creative tinkering. Together these minor, inexpensive modifications made a tremendous difference in squelching interior wind noise. I provided links to the supplies I used. Altogether I spent less than 30 bucks and an hour of work time.

Supplies:

1/4" x 5/16" D-section weatherstrip (https://a.co/d/eM1QD0v)

2" x 1" air conditioning foam (https://a.co/d/dpuvegQ)


6' foam pipe insulation tube (https://www.homedepot.com/s/3/4 inch pipe foam insulation?NCNI-5)

rubber end caps (https://a.co/d/12Uvby2)

silicone lubricant (KEZE Silicone Grease Automotive...)

STEP 1. As you can see in the photo. a postcard-sized sheet can slide through the side mounting mechanism of the Sunrider which means that outside air can enter here.

To seal the slight gap, open the top and remove the mounting bolts. Install 2" x 1" air conditioning foam (https://a.co/d/dpuvegQ) along the bottom of both gutters that run over the side windows (no adhesion needed).

STEP 2. To increase pressure from the Sunrider header on the secondary gasket at the windshield, add a double strip 1/4" x 5/16" D-section weatherstrip (https://a.co/d/eM1QD0v) across the Sunrider header (red arrows). LCW, another Bronco6G member, posted his solution: https://www.bronco6g.com/forum/threads/bestop-sunrider-wind-noise.33040/page-7. Be sure to clean the header area with isopropyl alcohol to assure adhesion. Also place a double strip (approx 3 3/4") at the very top edges of both sides of the header between the ridges on the roof material and the edges of the top (blue circle).

STEP 3. Install a single strip of 1/4" x 5/16" D-section weatherstrip (https://a.co/d/eM1QD0v) over the top of the Sunrider side mechanism from just under the back folding material to the front windshield gasket. This will further block wind entering under the side of the top. Be sure to thoroughly clean the surfaces with isopropyl alcohol to ensure proper adhesion.

STEP 4. Remove the plastic washers on both rear mounting bolts to eliminate the gap between the top and the rear of the Sunrider before retightening the bolts. This will allow the back of the top to compress against the roof seal. If appropriate for your situation, you can replace the 5.5mm plastic washers with 2mm thick ones (https://a.co/d/2V82Ra2) or thinner stainless fender washers.

STEP 5. Loosen the rear mounting bolts on both sides (red arrows) and loosen the center bracket bolts (green arrows), then tap the assembly rearward as much as possible with a rubber mallet (blue arrows) before retightening all the bolts. Sean Gloff posted the following instructions: https://www.bronco6g.com/forum/threads/bestop-sunrider-wind-noise.33040/page-2

STEP 6. Loosen the four front striker bolts (two on each side) at the front of the headliner (red arrows). Tap the strikers forward towards the windshield with a rubber mallet as much as possible (blue arrow) before retightening the four bolts. This will help pull the top down a bit tighter when latched. Again, thank you Sean Gloff: https://www.bronco6g.com/forum/threads/bestop-sunrider-wind-noise.33040/page-2

STEP 7. Flapping on the center cross bar can be fixed by opening the velcro and inserting a 1" wide x approximately 3' 2" long strip cut lengthwise from a 6' foam pipe insulation tube. (https://www.homedepot.com/s/3/4 inch pipe foam insulation?NCNI-5). Do not use any of the self adhesive surface to avoid a sticky mess during hot weather. Close the velcro material tightly against the crossbar and foam insulation.

STEP 8. The rivets used in the front brackets are too long, hitting and scratching the door header sheet metal. This could also affect optimal alignment of the top. File down the tips, clean the edges and place rubber end caps on both of the shortened rivet ends to avoid scraping. (https://a.co/d/12Uvby2). You will need to trim the length of the rubber tips for a snug fit.

STEP 9. Correct a leaky side window maladjustment with this simple procedure:


STEP 10. Thoroughly clean with isopropyl alcohol then rub silicone lubricant on all surfaces of the rubber molding along the whole length and width of the side windows and along the windshield header weatherstipping to soften the gaskets and provide a better seal. (KEZE Silicone Grease Automotive...)

This entire process really doesn't take all that much effort and it significantly reduces interior wind noise - at least for me. I hope you find this useful for your ride!

How old is your Sunrider? The 5.5mm spacer is no longer needed for newer 2 door Sunrider.

I confirmed the recent design change with Bestop support after seeing differences in the older install video, which specifies the spacer, and my new top which did not come with the washer, nor was one specified in the paper instructions.

I wonder what other improvements were made, perhaps to improve fit.

 

[horseplay]

Bought mine in May, 2023. Works great without the 5.5mm plastic washers.

 

[TheShark]

How old is your Sunrider? The 5.5mm spacer is no longer needed for newer 2 door Sunrider.

I confirmed the recent design change with Bestop support after seeing differences in the older install video, which specifies the spacer, and my new top which did not come with the washer, nor was one specified in the paper instructions.

I wonder what other improvements were made, perhaps to improve fit.

I just bought my 2dr Sunrider and that's the first thing I noticed was no plastic washers. I had a 2dr Sunrider on my '21 and sold it when I bought my '23 4dr, wouldn't have fit my '24 2dr anyway with all the changes they made. Something else I noticed, are the two metal side plates that bolt on the back, are those new? I just don't remember them from the '21, I remember the plate in the middle.

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