Aeromodding my 2003 "Classic" NHW11 Prius.

[basjoos]

If you carefully heat up that crease in the Coroplast with a heat gun while holding the bend angle you want, then when it cools, it will hold that angle.

[orange4boy]

If you carefully heat up that crease in the Coroplast with a heat gun while holding the bend angle you want, then when it cools, it will hold that angle.

Excellent. I bet it's also less likely to crack which happened on some of my outside corners.

By the way, the box skirts are holding up well. They get whacked quite a bit by ferry ramps and scraaaaaaped by tall speed bumps but they are none the worse for wear aside from the resultant scuffs. The coro seems flexible enough.

Even with the low clearance I have it's rare to hit anything on regular city streets and ramps. If you go slow enough over speed bumps they are not too bad. The ferry ramps are the only real serious clearance issue.

[Otto]

How about hinged side skirts, that would fold up against the floor pan of the car around town, but then fold down vertically for highway use?

[orange4boy]

I like the idea bit it would be difficult to do reliably.

I'm still hoping to do hinged front wheel skirts eventually. I love hinges.

[Frank]

So I've just read this whole thread but haven't seen any discussion on how much improvement you've realized. (I like your work BTW!) Your signature has a 50 mpUSg number and you've mentioned 62 mpg (I assume that's imperial i.e. ~51 mpUSg.) Do you have any test data on how much each mod has helped? You also mentioned coastdowns: any info from them?

I don't know what typical mileage the Gen I stock Prii got (our Gen II gets 52-58 mpUSg depending on the season.)

TIA

[PaleMelanesian]

All you're asking is right there, underneath his name.
2003 Toyota Prius Gas Mileage (Chewie) - EcoModder.com

[Frank]

Thanks - I didn't realize it was a clickable log....

[orange4boy]

Originally Posted by Frank

So I've just read this whole thread but haven't seen any discussion on how much improvement you've realized. (I like your work BTW!)

Thanks. It's quite difficult for me to do the kind of testing that, say, Darin does. I live on a small island where the only straight and level road is on the Ferry and trips to town are usually filled with visiting friends and shopping for groceries. I must remember to do some coastdowns at least though.

Your signature has a 50 mpUSg number and you've mentioned 62 mpg (I assume that's imperial i.e. ~51 mpUSg.)

That is actually 62 USmpg 74 imperial. Just on my last tank, mind you.

Do you have any test data on how much each mod has helped?

Since it's difficult for me to test I usually do a lot of research and do the numbers on a mod to see how much gain is possible. Then I have to let my mpg numbers do the talking. Of course my technique is improving so that makes a difference too.

I don't know what typical mileage the Gen I stock Prii got (our Gen II gets 52-58 mpUSg depending on the season.)

The EPA website shows an average of 45mpg for the 2003 from actual drivers who posted and 47.4 for the 2004 model. Sounds like you are doing great.

[orange4boy]

New pics of the car with all the goodies in place...



This is the slightly reduced wheel disc. I cut off about 1/2 inch and it now sits much closer to the wheel. I might do this all the way around. I will need to do this on the passenger side for sure to avoid destroying them on curbs. I already mashed one.

[Otto]

Ever get more specifics on that white plastic you used, from Home Depot or wherever?

I wonder if that stuff can be vacuum formed.