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Nice AeroCap!
electricman,
Nice work! I have to agree with you on how the interior noise level goes down, not to mention the increase in the fuel efficiency of your truck. I hope your friend can help you out with making the mold. From that, you can fabricate a durable part and not lose the nice shape you arrived at in foam.
We share a common line of work, Bizjets. I have been involved over the years in the construction of many full-scale business jet mockups mostly for Gulfstream Aerospace. The pictures below are from a few years back when we constructed the Gulfstream G-150 mockup. They are big much bigger than an aerocap and you don't find yourself sanding upside down with the pickup stuff.
I have to agree with you also on winkosmosis's idea, that would be cool!
Bondo
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