AeroCap

[BMac]

$52 worth of materials. I figure my mpg went up 2 or more but I also am running halo's and advanced the cam 4 degrees.

Now the rear end is trying to eat it's self so there's more work to be done! And since it's going in the garage, I'll be very busy

[Pinhead]

It would probably be more effective on a less aerodynamic vehicle. The First gen Rams and the Dakotas are very aerodynamic, for a pickup. I was thinking of trying to figure out how to make one for my '98 Ranger. Is it all fiberglass? How did you make the mold?

[daox]

Very nice! I too would like to know what materials you used.

[BMac]

I used 11/32" plywood, 1X4" and 1X2" wood to build. Only needed two sheets of plywood. The top one was only cut to length. The sides slanted from the outside edge of the box to 8" inside to meet the top as it turned down. The shape turned out awesome! Too bad I wasn't a body man. I designed it so it was easy to build. I doubt it weighs 150. I just get under it and through it on my broken back and throw it up on the truck.
$52 for materials. I can design one for you. I need inside/outside and cab back dimensions.

[E=mc2]

Good clean design. A little too late now...but I've found that doing a first coat of fiberglass resin on plywood with paint on top makes it handle weather real well. I also have used fiberglass tape at the seams.

Guess you can still open the tailgate?

You can also use oil tempered masonite with this kind of construction for sharper curves.

Maybe some vgs around the top and sides at the back might help?

[BMac]

Good clean design. A little too late now...but I've found that doing a first coat of fiberglass resin on plywood with paint on top makes it handle weather real well. I also have used fiberglass tape at the seams.

Guess you can still open the tailgate?

I was going to glass it first before paint but time and $$ running out. I had a trip to Detroit I had to make and was wanting to test it. This is just the first design anyway but turned out nice.

Yes, I can still open the tailgate but you have to watch your fingers!

[wadak1234]

Bmac,

Very nicely built indeed, it almost looks an inverted wide canoe or boat. Never the less, it looks very nice. Did you install the Halos and advance the cam at the same you installed the new aerodynamic top. I would be curios to know? I have a 97 dakota clubcab with a v6 and automatic. I would be interested to try a similar experiment to see if it made any difference in mileage. I am also running the Halos with an MSD system. Thanks,
Wadak

[BMac]

Wadak,
I did the Halo's, the cam advance and the cap all at once. I have an MSD system in there but couldn't get it to work after I put the engine/trans back in. Now I found the ground wire wasn't hooked up so I'll be running that again
Today I'll be re-installing the rear differential after a bearing failure rebuild (they say it's common ). I also got a 3" intake and cone filter installed and I built a heat shield for that.

I use to have to run mid grade fuel to have it run decent. With the cam advance I was expecting ping but heard none. I'm guessing the Halo's may have addressed that problem AND I'm running regular fuel

Just before I took the diff out for rebuild, I backed it out to the end of the driveway and was surprised how easy and little pedal I needed to smoke the tires Seems there's more torque = mpg!