Like bcbigfoot, I to have a 2nd generation Dodge/Bigfoot camper combination with a 5" to 6" gap between overhang and roof of truck. I had no noise issues in over 12 years of use. I is possible the difference in our rigs is why bcbigfoot had noise and I did not. My truck is a '96 Dodge 2500 Ext Cab long bed 2WD and my TC is a 11.5 foot 1500 Bigfoot. My TC is not as tall as the 2500 series which has a taller cab over and a basement. I can say, the 2nd gen Dodge trucks were notorious for air leaks at the top of the doors. Most of it, if not all, can be adjusted.
The main problems I have heard about is under the right circumstances, like entering or exiting exceptional steep driveways or similar conditions, the air dam will hit and damage the lights or roof of the cab. Not only is the initial mounting important, but over time the normal whipping action of the wind can break the dam loose from its mounting. The only damage I am aware of is to the mounting area of the TC and possibly scratches to the paint on the cab of the truck.
A thought to ponder. How close to the cab must you mount the air dam for it to be effective? The typical up and down movement on my TC cab over is probably 1" to 2". bcbigfoot appears happy with his, with no negative issues. I suggest you ask him for details on how he fabricated his, a new thread would be great. There is always members interested in "how tos".
Wayne
