Is the only trick to installing the header correctly to push it as far forward as possible before tightening down?
I have tried removing and reinstalling with no luck and it is just strange that we are only having wind noise on the drivers side corner.

 

You have to make sure that it is not only as far forward as possible, but square to header seal on the windshield frame. If it angles back, even a little bit, wind noise is amplified. Next, buy a roll of 1" wide weather stripping (Autozone, or any similar store carries it). Cut a length about 3" long. Tear off the paper backing and stick it along the top where the upper forward corner of the door seal contacts the top. This will further reduce wind noise.

I'll post some photos when I can get to a camera, later today.

 

Widewing, any chance you were able to get those pictures?

 

I'll get some tomorrow... Very busy weekend here. My daughter and grand daughter arrived from Hawaii on Friday... Non-stop since.

 

Are you talking about switching the washers because the hole was too large for it to be secure using that little hex washer because that is what I had to do.

 

I folded the little tabs at the front that have the foam backing on them up under the header on each side & made mine MUCH quieter. It made a huge difference. I got that idea from someone on this forum in another thread. I'd give him credit if I remembered who it was. Mine is very quiet now!

 

Turn the radio up.

corey d

 

Okay, here's two shots showing the weather stripping in place. This significantly cut down noise at the corners of the windshield frame. Also, the corners are completely weather-proof. No rain water gets in under the worst conditions.

 

X2...I also read about this trick and it works very well

 

I wonder if the OEM door surrounds would be helpful?