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<blockquote data-quote="jswong" data-source="post: 1600320" data-attributes="member: 8004"><p>Instead of using bintumen strips and foam sheets that have no heft, I resorted to using urethane foam + rubber mats</p><p></p><p>Generic rubber mats from accessory shops or hypermarts = RM10 for a set of 4 mats</p><p>Urethane foam = RM22 for a big can of Great Stuff from Ace Hardware</p><p></p><p>I just cut the rubber mats in half - one for the top half of the door, and one for the bottom half. Wira's door has a bar in between, so I had to do this.</p><p></p><p>I slid in the rubber mats into the desired location, peeled it forward and sprayed some urethane foam underneath. The rubber mat is then pressed against the urethane foam, and I slid it back and forth and up and down to spread the urethane foam evenly between the mat and the door. By the way, the mat was applied with the 'hollow' side (the one with lots of open squares) facing the door, so that the expanding foam can fill the gaps as a 'key' surface to stick against.</p><p></p><p>Once the urethane foam cures, the rubber mats aren't going anywhere. It sticks really well, and the rubber mats make the door heavier. The urethane foam tends to absorb vibration (since it's a low-density closed cell foam) while the heavy rubber mats deaden vibration and noise.</p><p></p><p>The result - road noise reduced by A LOT. And this method is very, very cheap, but it could get messy as cured urethane foam cannot be removed by any solvent.</p><p></p><p>Wind noise is a problem of wind getting past the rubber linings. I suppose the solution would be to add an additional surface between the car body and the door's rubber linings to seal out wind more effectively.</p><p></p><p>I'm thinking of trying out butyl rubber caulk. Butyl rubber remains flexible and soft when cured, and it can adhere fairly well to most surfaces. Maybe I can caulk a 3mm bead around the door area, and let it cure. It should form a tighter seal against the door's rubber linings, and hopefully it can keep out wind noise.</p></blockquote><p></p>
[QUOTE="jswong, post: 1600320, member: 8004"] Instead of using bintumen strips and foam sheets that have no heft, I resorted to using urethane foam + rubber mats Generic rubber mats from accessory shops or hypermarts = RM10 for a set of 4 mats Urethane foam = RM22 for a big can of Great Stuff from Ace Hardware I just cut the rubber mats in half - one for the top half of the door, and one for the bottom half. Wira's door has a bar in between, so I had to do this. I slid in the rubber mats into the desired location, peeled it forward and sprayed some urethane foam underneath. The rubber mat is then pressed against the urethane foam, and I slid it back and forth and up and down to spread the urethane foam evenly between the mat and the door. By the way, the mat was applied with the 'hollow' side (the one with lots of open squares) facing the door, so that the expanding foam can fill the gaps as a 'key' surface to stick against. Once the urethane foam cures, the rubber mats aren't going anywhere. It sticks really well, and the rubber mats make the door heavier. The urethane foam tends to absorb vibration (since it's a low-density closed cell foam) while the heavy rubber mats deaden vibration and noise. The result - road noise reduced by A LOT. And this method is very, very cheap, but it could get messy as cured urethane foam cannot be removed by any solvent. Wind noise is a problem of wind getting past the rubber linings. I suppose the solution would be to add an additional surface between the car body and the door's rubber linings to seal out wind more effectively. I'm thinking of trying out butyl rubber caulk. Butyl rubber remains flexible and soft when cured, and it can adhere fairly well to most surfaces. Maybe I can caulk a 3mm bead around the door area, and let it cure. It should form a tighter seal against the door's rubber linings, and hopefully it can keep out wind noise. [/QUOTE]
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