Commercially produced aerodynamic pickup bed cap

[MetroMPG]

Brett replied to my post:

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Originally Posted by bondo

Thanks Darin for the kind words. I appreciate all who frequent this board. I have learned alot from others by reading the posts and I am glad you feel my posts have made a contribution. Thank you for posting Phil Knox's info. I met Phil back in 2005. Gr
eat guy. As I have said before, he has forgotten more than I will ever know about aerodynamics.

Brett

[johnpr]

ahhh, didnt realize there was an issue with the server i hope it wasn't very costly.

[bennelson]

I am interested in making a home-built version of Bondo's super-cool truck capper.

I was originally thinking using coroplast. My S10 is white, and that's one of the stock colors you can get it in.

One thing I like about the S10 is that you have great visibility looking out the back and checking blind-spots. Any type of a cap would greatly reduce this.

What do you think of making the entire top-angled part of the cap out of plexiglass or acrylic? Or at lease making a REALLY BIG window in it. Bondo's design is great, but those windows sure look small to me.

I know that there are various materials used for greenhouses. Maybe there is some sort of greenhouse material that would make a great aero-cap and still keep good visibility?

[MetroMPG]

I've seen one made from lexan. I'll track down a picture.

[bondo]

Originally Posted by bennelson

I am interested in making a home-built version of Bondo's super-cool truck capper.

I was originally thinking using coroplast. My S10 is white, and that's one of the stock colors you can get it in.

One thing I like about the S10 is that you have great visibility looking out the back and checking blind-spots. Any type of a cap would greatly reduce this.

What do you think of making the entire top-angled part of the cap out of plexiglass or acrylic? Or at lease making a REALLY BIG window in it. Bondo's design is great, but those windows sure look small to me.

I know that there are various materials used for greenhouses. Maybe there is some sort of greenhouse material that would make a great aero-cap and still keep good visibility?

Bennelson,

You're right. Rearward visibility is very limited on the prototype aero cap. I have installed larger windows in the production design. Darin mentioned the see thru aero cap he had seen. I have pics of it somewhere also and will see if I can find them.

If you choose to use a clear plastic, make sure it is polycarbonate (lexan). Acrylic can shatter like glass and break up in large sharp edged pieces. The best remedy I have found for seeing while backing up is the $90.00 backup camera sold at Wal Mart. I have had mine installed since I put the prototype on my truck back in April of last year. Easy to install, works great!

Brett

[WaxyChicken]

Hey, Bondo, If i get a pickup truck later on then would i be able to order a Aero-Cap from you if i provide the measurements for the bed/cab?
(just something I'm considering)

[bennelson]

Another way of doing a "home-brew" version of this cap might be to build a lightweight (aluminum?) frame and covering it with shrinkable plastic.

Do you think the material from those "window insulation kits" would be durable enough? You can buy those cheap at the end of every winter. Being clear, they wouldn't restrict visuals at all. Wouldn't be good for locking things up in the back of the truck the way a hard top can, but we are speaking aerodynamics here..

Otherwise, how about the shrink material used for model airplane wings? It's sturdier and comes in different colors. I am not sure about the expense or the size that material is available in.

[bondo]

Originally Posted by WaxyChicken

Hey, Bondo, If i get a pickup truck later on then would i be able to order a Aero-Cap from you if i provide the measurements for the bed/cab?
(just something I'm considering)

Hey Waxy,

If you choose to get a 2005 -2008 F150 6.5 foot bed, I can fix you up now. Next we are doing tooling for the 2007 - 2008 Tundra, so if you maybe getting a Tundra we can fix you up by July of this year. Next if you choose to get a Chevy or GMC 2006-2008 we can fix you up by fall of this year.

Due to the hundreds of man hours required for tooling, a custom job would be very expensive. If I can be of any help if you choose to DIY, I will be glad to help by lending you any advice I can.

I have chosen not to take the lucrative contract job I spoke of earlier on page one of this thread. I have now commited to get the aero cap to market. There comes a time in everyones life when you just have to see what you are made of. That time for me is now.

Brett

[SVOboy]

Strong words brett! Good luck,

[WaxyChicken]

You win or loose, but you never fail if you give a real effort.

[bondo]

Thanks for the encouraging words guys. The old song goes, "I get by with a little help from my friends", is so true.

In addition to you guys, my good friend has quit GM Design in California and come to Arkansas and help me get initial production set up. As we bolted shelves together today he and I realized we will just have to work only half a day. The problem will be whether to work the first half of the day or the second 12 hours.

Thanks for wishing us good luck,

Brett

[DifferentPointofView]

bondo, I like your design for the tundra, but it'd look even nicer if you made the side windows for each vehicle go with the door windows on the tundra. the tundra has more square-to-triangle windows and the ones on the cap are more rhombus. if you continued from where the windows end, you could make it flow more naturally with the design of the truck. you'd have better visability, and it make it look more "from the factory"

[bondo]

DifferentPOV,

You are so right about the windows. We have a generic design drawn up for a new better styled side window like you speak of. Tooling for new windows is very expensive and until we get some sales it is just not doable. Initially, we will have to rely on off the shelf windows.

Definitely a "catch 22"! Better looking windows, which go with the host vehicle, would be more attractive and increase sales!!!! Here's a pic of a template for the new generic side window on the F150 prototype.

Brett

[DifferentPointofView]

Good to hear your doing what you wanna really do tho! afterall, winners find a way right? hope it all goes well!

[MetroMPG]

Congrats on the big decision, Brett. We're behind you.

Is the photo of the Toyota a digitally altered image, or a real bed cover?

I can see an image of a Prius next to the Tundra comparing rooflines for marketing purposes.

[bondo]

Thanks Darin,

My decision to go ahead was helped by the great response I have gotten from ecomodder. Thanks again for putting up this post on my lid.

The image of the Toyota is the aero cap off my truck super imposed on a picture of Tundra I took at the local dealer. The new Tundra gets pretty bad gas milage. I am looking forward to see if the aero cap shows about the same increase on the Tundra as it has on the F150.

I like your idea of a Prius and a Tundra with an aero cap on it beside it. Marketing is always so very important.

Brett

[bestmapman]

Originally Posted by bondo

Thanks Darin,

My decision to go ahead was helped by the great response I have gotten from ecomodder. Thanks again for putting up this post on my lid.

The image of the Toyota is the aero cap off my truck super imposed on a picture of Tundra I took at the local dealer. The new Tundra gets pretty bad gas milage. I am looking forward to see if the aero cap shows about the same increase on the Tundra as it has on the F150.

I like your idea of a Prius and a Tundra with an aero cap on it beside it. Marketing is always so very important.

Brett

Good luck, I hope you do well.

[bennelson]

Does this look familiar?

Maybe the pickup would get better mileage with the Citicar spun the other way!?!?

Get better economy AND have a getaway car for your pickup...

[MetroMPG]

Ben - here's the picture I was remembering.



Bed cover & mobile greenhouse!

[DifferentPointofView]

HOLY SNAP!!! that looks beautiful.... *teardrop* What's it made out of?