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Old 03-05-2011, 06:34 PM   #101 (permalink)
T-100 Road Warrior
 
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BZP T-100 (2010) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
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90 day: 20.6 mpg (US)

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BZP T-100 (2015) - '98 Toyota T-100 SR5
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Pulled the aero cap apart and have started tapering the rear a little bit. Since I made the aero cap modular, I just had to take out some screws and pivot the sides in. Some support straps to fix it in place, measure some new panels and screw them in. Redo the hatch fer the new setup. I'm looking at pulling the sides in about 6"...12" overall.

A rough estimate on the left side...




The cap opening will be about 48" wide at the rear.

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Old 03-05-2011, 09:46 PM   #102 (permalink)
T-100 Road Warrior
 
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BZP T-100 (2010) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
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Last 3: 23.66 mpg (US)

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Last 3: 19.01 mpg (US)

BZP T-100 (2012) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
90 day: 19.68 mpg (US)

BZP T-100 (2013) - '98 Toyota T-100 SR5
90 day: 20.6 mpg (US)

BZP T-100 (2014) - '98 Toyota T-100 SR5
90 day: 21.28 mpg (US)

BZP T-100 (2015) - '98 Toyota T-100 SR5
90 day: 20.56 mpg (US)

BZP T-100 (2016) - '98 Toyota T-100 SR5
90 day: 20.54 mpg (US)

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A little closer to closing it up...pulled it in about 6" from both sides.



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Old 03-05-2011, 10:05 PM   #103 (permalink)
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Wow, too bad mine is disassembled and under about 3 feet of snow right now, or I'd put up some pics of it... looks very similar to what I built, coroplast over wood and everything. Mine has no "twist" on the sides though, and in side view the top has an arch, not straight...
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Old 03-05-2011, 10:34 PM   #104 (permalink)
T-100 Road Warrior
 
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BZP T-100 (2010) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
90 day: 20.99 mpg (US)

BZP T-100 (2011) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
Last 3: 23.66 mpg (US)

BZP T-100 (2009) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
Last 3: 19.01 mpg (US)

BZP T-100 (2012) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
90 day: 19.68 mpg (US)

BZP T-100 (2013) - '98 Toyota T-100 SR5
90 day: 20.6 mpg (US)

BZP T-100 (2014) - '98 Toyota T-100 SR5
90 day: 21.28 mpg (US)

BZP T-100 (2015) - '98 Toyota T-100 SR5
90 day: 20.56 mpg (US)

BZP T-100 (2016) - '98 Toyota T-100 SR5
90 day: 20.54 mpg (US)

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My hatch will still have the arc...I just haven't gotten to finalizing my sides yet. I'll post up piccies when I git to that stage though...
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Old 03-07-2011, 10:56 PM   #105 (permalink)
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BZP T-100 (2010) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
90 day: 20.99 mpg (US)

BZP T-100 (2011) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
Last 3: 23.66 mpg (US)

BZP T-100 (2009) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
Last 3: 19.01 mpg (US)

BZP T-100 (2012) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
90 day: 19.68 mpg (US)

BZP T-100 (2013) - '98 Toyota T-100 SR5
90 day: 20.6 mpg (US)

BZP T-100 (2014) - '98 Toyota T-100 SR5
90 day: 21.28 mpg (US)

BZP T-100 (2015) - '98 Toyota T-100 SR5
90 day: 20.56 mpg (US)

BZP T-100 (2016) - '98 Toyota T-100 SR5
90 day: 20.54 mpg (US)

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Progress fer today...

Had to take the hatch apart since the aero cap dimensions had changed. Since putting the original together...I learned a lot and applied it to this version. It's a little more accurate as far as measurements go...

Hatch frame resized...


Decided to lose the 2 extra sheets of 4x8 Coroplast from the original setup and made some 5" strips to take their place...


Main cover back on...only a single 4x8 sheet!


Used hot glue as a basic sealer fer the sides...the duct tape is just a temporary gap filler.


I still have to put in the rear window and hook up the interior lighting. I might end up trimming the back end a little...not exactly sure yet.
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Old 03-23-2011, 12:02 AM   #106 (permalink)
T-100 Road Warrior
 
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BZP T-100 (2010) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
90 day: 20.99 mpg (US)

BZP T-100 (2011) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
Last 3: 23.66 mpg (US)

BZP T-100 (2009) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
Last 3: 19.01 mpg (US)

BZP T-100 (2012) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
90 day: 19.68 mpg (US)

BZP T-100 (2013) - '98 Toyota T-100 SR5
90 day: 20.6 mpg (US)

BZP T-100 (2014) - '98 Toyota T-100 SR5
90 day: 21.28 mpg (US)

BZP T-100 (2015) - '98 Toyota T-100 SR5
90 day: 20.56 mpg (US)

BZP T-100 (2016) - '98 Toyota T-100 SR5
90 day: 20.54 mpg (US)

BZP T-100 current (2017) - '98 Toyota T-100 SR5
90 day: 19.38 mpg (US)
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The aero cap held up pretty well...until I encountered some heavy winds just South of Dallas. The hatch main supports were bowing up pretty badly...so I had to pull off the road and tape the entire hatch down just in case the main hatch exploded. Made it home without any incidents!

Now before I take this version apart and start working on my next version...I'm putting the 2 extra sheets of Coroplast back on top of the hatch to see if it will stabilize the bowing and flexing I was seeing as I was driving.

You can see the bowing here...this was at 65mph and about a 30mph crosswind...
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Old 05-19-2011, 10:19 AM   #107 (permalink)
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Hello,

Just joined this forum and have been doing a lot of research and kept finding things I'd do different until I saw your shell. You must be an engineer. You've got the slope right and the over hang and the side skirts. Have some closer pics? Have you posted details on your mods. Can't find any??

I've got a Tacoma. Could use your help. Where did you find your air dam and how did you make your side skirts? It looks very well done.

I've started on an aero shell, but am wrestling with materials right now.

Thanks!
David minAirForce
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Old 05-19-2011, 10:34 PM   #108 (permalink)
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Join Date: Apr 2008
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BZP T-100 (2010) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
90 day: 20.99 mpg (US)

BZP T-100 (2011) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
Last 3: 23.66 mpg (US)

BZP T-100 (2009) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
Last 3: 19.01 mpg (US)

BZP T-100 (2012) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
90 day: 19.68 mpg (US)

BZP T-100 (2013) - '98 Toyota T-100 SR5
90 day: 20.6 mpg (US)

BZP T-100 (2014) - '98 Toyota T-100 SR5
90 day: 21.28 mpg (US)

BZP T-100 (2015) - '98 Toyota T-100 SR5
90 day: 20.56 mpg (US)

BZP T-100 (2016) - '98 Toyota T-100 SR5
90 day: 20.54 mpg (US)

BZP T-100 current (2017) - '98 Toyota T-100 SR5
90 day: 19.38 mpg (US)
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Quote:
Originally Posted by minAirForce View Post
Hello,

Just joined this forum and have been doing a lot of research and kept finding things I'd do different until I saw your shell. You must be an engineer. You've got the slope right and the over hang and the side skirts. Have some closer pics? Have you posted details on your mods. Can't find any??

I've got a Tacoma. Could use your help. Where did you find your air dam and how did you make your side skirts? It looks very well done.

I've started on an aero shell, but am wrestling with materials right now.

Thanks!
David minAirForce
I'm not an engineer...

I did make my own extended air dam...

Since you have a Tacoma...I don't think you can use the same method of attaching yer aero cap to yer bed in the same manner as I have (I used the stake pockets).

Most of my build is over at ToyotaNation. I try to mirror some of it over here in this forum. Here's a few of my threads that might give you some answers...

Modified air dam... - Toyota Nation Forum : Toyota Car and Truck Forums
Under belly pan... - Toyota Nation Forum : Toyota Car and Truck Forums
My attempt at an aero cap... - Toyota Nation Forum : Toyota Car and Truck Forums
Oil catch can/system... - Toyota Nation Forum : Toyota Car and Truck Forums
Extended air dam... - GasSavers.org - Helping You Save at the Pump Hypermiling and Fuel Efficiency Forum
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Old 05-21-2011, 09:51 PM   #109 (permalink)
T-100 Road Warrior
 
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BZP T-100 (2010) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
90 day: 20.99 mpg (US)

BZP T-100 (2011) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
Last 3: 23.66 mpg (US)

BZP T-100 (2009) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
Last 3: 19.01 mpg (US)

BZP T-100 (2012) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
90 day: 19.68 mpg (US)

BZP T-100 (2013) - '98 Toyota T-100 SR5
90 day: 20.6 mpg (US)

BZP T-100 (2014) - '98 Toyota T-100 SR5
90 day: 21.28 mpg (US)

BZP T-100 (2015) - '98 Toyota T-100 SR5
90 day: 20.56 mpg (US)

BZP T-100 (2016) - '98 Toyota T-100 SR5
90 day: 20.54 mpg (US)

BZP T-100 current (2017) - '98 Toyota T-100 SR5
90 day: 19.38 mpg (US)
Thanks: 3,072
Thanked 1,294 Times in 906 Posts
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Added in some support to the hatch...the airflow over the top during some instances would severely push down on the skin and looked like it would collapse.


It's basically some " Sch 40 PVC pipe that I cut and just wedged in there. A few screws to hold it in place. It's basically fer testing.
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Old 05-22-2011, 10:46 AM   #110 (permalink)
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Keep up the good work. Love the incremental updates.

The buckling under way intrigues me. I wonder if it's positive pressure above or negative pressure below. Have you been able to tuft test that area with a chase car for example?

Rock on!

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