91 Dodge airocap

[gumby79]

Deejaaa
Gumby nickname from high school
next question Better mpg?
answer: yes
explanation of how I got said answer
I got #2and3 top mpg for lifetime fuel log driving 880miles@60-65 for 2 tanks of fuel
hear are pic of dirty air on a airocap

https://plus.google.com/+daviddroesc...ts/1a2i9KkArPz

loaded 5520 tair7160 gross
7160# gross = truck + passengers + load +fule (per Or state DOT scale)
-5520# tare = me + truck full tank fuel (per WA state DOT scale )
--------
1560# cargo

550el to 5600el 22.22 up continental divide dated 05/07/15 compared with down @23.01

https://plus.google.com/+daviddroesc...ts/JH9BGv9jRqe


compared with down @23.01

west bound going home in jan 5 months ago. life time best dropping down "the continental divide ( highest place in America) to sea level

[BamZipPow]

Just be careful of how long the material will last. While the shrink wrap has some UV protection, it's not rated fer the wind loads and temps over time that you will be subjecting it to on the road. You will need to inspect it carefully each time you go out and know that as you approach the 6 month mark, it may need to be replaced. I have some reservations of the material lasting more than a year.

[gumby79]

With any luck by 1 year in I will he happy with my shapes and can spend $76.95usd Approximately 1 yd² / linear meter for the material in post#6 $76.95 USD ORATEX 6000 . ORATEX 600 @$54.95 Approximately 1 yd² / linear meter +shiping from Germany. as well as a small list of consumables.

Website Oratex: The Better Aircraft Fabric

[deejaaa]

i'm surprised it weighs 150lbs. is the frame steel rod?
i like your idea and will keep this in mind. i imagine i could make a frame and use that material to make a kammback. lightweight and easy to use. plus my car is white.
when it's heated, will it only stick to itself or would it also stick to a painted surface?

[gumby79]

Deejaaaa
it is melted to gether (thermal welding) I used a mini torch to spot weld then heat gun to finish the seem after that grass torch to shrink

yes it only sticks to it self not paint

The ORATEX uses special adhesive similar toPiper J-3 Cub aircraft

[gumby79]

Deejaaaa
as for weight this is designed as two parts.

A standalone headache rack capable as any on a ranch truck. With an airodinamic twist (the sides of the headache rack are tapered and only 15 □" of added frontal area)

headache rack~40-60lbs: 1"x3" .065 steel with 3/8 plexiglass 20"x20" cutout for the pass through window

canapé ~35 lbs :1/2"id .065" tube for sparse 5@ 9' +~20' for cross bracing and tail extension radius + 1"x1" .065 square 30' for frame + 50 3"x3" .065 corner gussets. The canapé can support my 190lbs (tested on shop floor before covering lol).

The final product will be able to be raised and locked up as a wing for towing an enclosed trailer (as most Comercial units camper or box have a flat front ) ever tow a box trailer with a VW Bug not easy

Bang zip pow Check out about the oratex https://youtu.be/GJ-KHRHlRDg

[gumby79]

Well!! action speaks louder than words.

This comparison is the info in my fule log from Dec 31,2014 through June 20,2015 1st 6 months of ownership

1991 Dodge D 250 first gen cummins LE Gas Mileage (little jona) - EcoModder.com

Bone stock as dodge buld it.
2501mi 137.140 Gal. 46+ oz CETANE booster =18.237 mpga ( miles per gallon average)

in all conditions, loads, weather, grades, and speeds

This includes exost wrap (not stock)

VS

Airocap with all stock w/exost wrap

5062mi 219.451Gal. 75+oz CETANE booster = 23.067 mpga ( miles per gallon average)
in all conditions, loads, weather, grades, and speeds

Lifetime Fuel Economy: 22.3 mpg (US), 10.5 L/100 km, 26.8 mpg (Imp)
90-day Fuel Ec

I am planning an ABAB TEST later this summer however wile on the road. The canapé is not ssomething that I should leave tied to a tree till I get back past that part of the country.

[gumby79]

The comparison of fuel economy if I strike the two highest and the two lowest is 20. 5 22 miles per gallon average stock
VS
23.6 26 miles per gallon average w/ the airocap

[gumby79]

While in Las Vegas NV temps were geting over110°f and the plastic relaxed Slightly about 1/4" so I used some "light"tan hammer tone plastic compatible rattle can paint. Painted over the wight duct tape burn hole patches. Figured it would help as sunscreen spf 100. Maby. However much ro my dismay it turned out a dark copper. So during my 2nd trip to LV the heat sag was much larger problem @ about 117°f it would sag about .5" on the 2 center spans at the hottest part of the day. But the plastics would go back to tight after about 1-5min of driving got back to the soggy cool NWand it was back to a snear drum.


BamZipPow you called it 6months. However the Oratex has been tested past 10years passing FAA testing so it will work for the long hual. Srick and shrink repairable easy compound curves
Hear is a hammer test with the Oratex I found. http://https://youtu.be/yoI5PEIxtEg


Well 6 months in I saw 3/4" crack form in week spots only(over heated cussing it to thin after thickening)


tube from a 4 in. fat tire bike as a gap filler
May up to pool noodles I didnt account for rhe forward lean of the back of the cab v2.0 will.
The last 2 are learning curve errors
paint chiped off from improper attachment

The missing paint(bright spots) was caused by the bace plastic changing to much strechmarks given time theas would become cracks justified an extra 10# of steal fraim work
wasn't melted well enough and separated nextto hot

Changes for v1.2
Added 1/2" Millar backed fome between the fraim and plastic. It softened the allmity side to top transition and noise suppression
Added an inner hoop for mounting point.
Added lift struts.
Added a latch mechanism
Added Garage goor seal for bededge seal

Total weight for moving part is 35# V1.0 was 21#

[gumby79]

Had 4" of power fall and decided to do an air flow test

these were taken after 2mi at 25 mph and 1mi at 45mph out side Anaconda, MT

notice the vortex patterns at the transition from horizontal to vertical

I only cleared the snow from the windshield, side windows and hood



these were taken near Wisdom, MT 10mi at 60mph
the first one shows the air attachment going to the tail in the horizontal plain and warping in in the back from vertical




a small disturbance behind the hinge other wise it looks like the "ladder rack" [part that protrudes above the cab ] dues not create much disturbance , as expected some but small. the air is steal able to stay attached

these were taken at Georgetown lake speeds of up to 70mph

this shows the termination past the tailgate after I built the canape I noticed that "ALL" the new trucked have a similar shape added to the top of the tailgate depending on the make from 2"-6" to help brake the vacuum bubble at the tailgate


and to show why a 2 piece canape. It's a truck its gotto be able to work. 30 70lbs bails of hay

so far I'm avraging 24mpgs on the flats with a 22mpg low and 27.9mpg all time high