After fitting the light bar I later discovered the wind noise was actually from the bar itself, rather than the holes for the lights. It does sit a lot closer to the roof than the genuine one so the potential for noise is much greater.
Years ago I rescued some tinted plexiglass from a skip at work, and I finally had a use for it. A few passes with jigsaw and sander and using some rubber sleeved cable clamps, I had a working wind deflector. Works brilliantly, keeping noise under control at suitable motorway speeds.
I was tempted to get some white letters and brand it "PHOOL" (as homage to Thule) but decided against it.
The last thing to make was a roof rack extension, which links the rear rack to the light bar.
Whilst not too bad to make (I must be getting better at this welding lark), I'm slightly disappointed as to how it connects to the rear rack. I was hoping for it to meet the crossbar on the front face, but I made an error with the cut and welded angled join at the front, making the bars run lower than planned. They still allow the sunroofs to open so it's not all bad.
It does look a bit "LETS OFF-ROAD!", but it's a belt and braces method of keeping the light bar in one place, and it also provides a route for the light wiring when I start on that.
If I need to remove the sunroof panels (I've not needed to so far) it's just a couple of bolts to undo / slacken.
