I just posted a lengthy comment on our sister GR86 Forum re: this frustrating subject, and to be fair (since I originated this thread), I'm going to just "copy/paste" the same comment here, for those who may be interested. Here it is:
Interesting recent postings by some keen enthusiasts since I last checked this thread. Seems like we're coming to some sort of consensus overall, which is both good and bad. The good is that I think we are all reaching a level of exhaustion in trying to find a workable, and durable, solution to the infamous "tire/road noise" issue, and we need a break. But, the bad is that many of us have yet to find the relief from objectionable noises while driving our cars on rough-textured roads. So, a few comments to summarize my feelings, and experiences, at this point, FWIW:
1. I believe the vast majority of second gen. BRZ/GR86 owners are not at all troubled by the noise issue. I believe this is because the noise only appears when driving these cars on harsher concrete road surfaces that are only found in certain areas of the U.S., and evidentlyt in other countries as well. I live just north of Seattle, WA, and I can promise you that the majority of the highways out here are anything but "smooth". But, just today, I encountered a patch of smooth blacktop on a section of I-5 that had been laid as a temporary "fix" while other sections of the highway were being repaired. There was absolutely NONE of the noise along this short stretch, but as soon as I got back onto the "normal" concrete, all hell broke loose once again. Is this the car's fault? Or, is it the road surface?
2. I have now tried three different sets of tires on my '23 BRZ Limited: (a) the OEM Michelin PS 4's, (b) the Continental Ext. Cont. DWS06 that was ballyhooed by many, and now the Pirelli P-Zero A/S +3 that the Tire Rack had found was the quietest of nine different UHP A/S tires. I will never mount the PS4's again, but I'm sad to say so because I have had nothing but great luck with all manner of Michelin tires on my cars for many years. Those tires are just too harsh, unforgiving, and loud for my tastes. Likewise, I see no reason to return to the Continentals, as the noise reduction with those, if any, was infinitessimally small when compared to the PS4's, IMO. For now, I'm sticking with the Pirellis, as I did find them to ride a bit less harshly than the other two, and I preferred the steering feel of them as well. Unfortunately, the overall noise levels, measured with my phone app, were indistinguishably similar for all three. I'm now DONE with trying different tires. The problem lies within the car itself, but only when the car is traversing rough-surfaced concrete or "chip seal" roadways. And, I doubt I can convince the state of Washington to repave most of its interstate highway system!
3. In desperation, I did finally try modifying the stock V-braces on my car. I bored a single large hole into the "top" of each V-bar close to the firewall mounting end, and I carefully filled each bar with dry sand, packing it inside as much as possible. I sealed each hole with a round rubber seal (like a grommet without a hole) that fit tightly, but I reinforced it with a wrap of zip-tire across each seal, just to be sure. I recorded a "test sound" between the filled and un-filled bars, while both werre suspended in space on a large screwdriver. After rapping each bar with a metal hammer, the sound-deadener effect was definitely apparent. I will try to attach a video below. But, after re-mounting both filled and deadened bars on the car, I found the reduction in humming and howling to be almost imperceptible. I should also add that driving without the bars in place at all produced very little improvement in noise levels as well. So, I tried to attach the 20 sec. iphone video, but it was rejected. Wrong "extension", and I'm too much of a Luddite to figure out how to modify it. The sand changed the sound from a high-pitched "ring", to more of a muffled "thud", but it still didn't solve the car's problem.
4. I may yet give the Nameless V-bars, and maybe even the Nameless strut tower bars (front and rear) a try, as good reports have appeared in favor of them. I doubt the problem will be resolved, and after that, if I'm still too frustrated, I may try the application of sound-deadening materials here and there. Mostly, I'm going to focus, like @CiscoESP suggested, on just enjoying driving my car on whatever better roads I can find in my area.
Thanks to all who have contributed to this lengthy discussion. Maybe an effective solution will be found some day, as there is obviously a ton of activity going on in the aftermarket re: our "twins".