Update
8 months ago my traction battery was dropped to fix a heat issue. When I got the car back from the dealer I noticed some of the carpeting wasn't fitting in the trim, other minor interior scuff AND a small crack in the trim around the front storage bin. Nothing worth complaining to them about. I was and am still happy they successfully completed a major repair that they probably hadn't done before. I barely drive this car so I don't get on the highway much and I'm not much of a speeder so it took me a while to notice the flapping sound I mentioned. I also didn't want to bother the busy people on the board with what seemed like an easy problem to diagnose--just figure out what is loose in the frunk. Everything looked good so occasionally I would tape down random things and do a little speeding to see if I had pinpointed the problem. No luck. Then I drove on a highway where everyone was going excessively fast. I also took a few highway trips during VERY windy days. During those trips the frunk flapping sound became so fast and loud that that the steering wheel was vibrating and the entire windshield seemed like it was rattling. I also heard bursts of air around the windshield so I convinced myself there was some rubber gasket or patch of glue somewhere around the windshield that was loose. I didn't bring it to the dealer because everything in and around the windshield/frunk/air vent seemed as it should and the occasional video I made didn't come out too well. In short, I didn't expect them know what the issue was from my description or to be able to replicate the problem from a normal drive. Thinking this could eventually become a safety concern for another driver on the road or myself I finally started this thread.
I wrote all that to explain why I worded the original post the way I did. I also wanted to really thank everyone who responded and to apologize for steering you guys in the direction of a windshield issue that didn't exist. I certainly learned a few obvious lessons from this and can't help feeling kinda... what's the opposite of smart? But maybe this post will help someone with a similar problem in the future.
Oh, and if you haven't figured it out... LOBSTER WAS RIGHT! (I think) The car is currently at the dealer for this and other issues I so can't definitively say it's fixed but 2hrs before I dropped the car off yesterday Lobsters post finally made me take took a closer look inside the front grill air duct and well... he knows what I saw. "If the bin has been removed and incorrectly reinstalled with this trim panel placed above the grill, the flexible rubber leading edge can lift and flap against the grill at high speeds. So happy I was able to show them the quick fix that was needed instead of sending them on a wild gooseshield chase. Thanks Lobster for nicely agreeing it could the windshield... "Frank, your windscreen air leak diagnosis may be correct and a likely a warranty fix..." even though I suspect you knew it wasn't. Cheers to you Steve, Slam, Ayepace, Sciencegeek, etc etc!
