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Old 03-19-2013, 02:20 PM   #11 (permalink)
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Try a sign shop. I was able to get a 4x8 sheet of lexan near me from a shop that builds commercial signs.

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Old 03-19-2013, 11:24 PM   #12 (permalink)
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$130 for a 4x8 sheet of 3/16" Lexan. Wow! Guess I'll have smaller windows than I had planned...
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Old 03-20-2013, 01:20 AM   #13 (permalink)
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Don't count out vehicle sunroof glass at the parts yard. You'll have to do a lot of research to see what might work. Don't even think about cutting it as it is tempered glass and it will shatter.

I was checking out the Maxima's glass sunroof piece. It might work fer yer aero cap as well.



Mounting it might be a little more difficult depending on yer skill set.
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Old 03-20-2013, 12:38 PM   #14 (permalink)
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Great minds think alike. For the forward window, I'll just grab the back glass from another S10/Sonoma. A few bone yards around here quoted me $40 if I pull it. I'll just mount the window in the same orientation as the existing back glass, and it should line right up. For the rear glass, I'll have to do some digging and find something that will match. I have a 2x2 piece of Lexan in the attic that would do the trick if I add a center divider. That might be my only reasonable option.
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Old 03-26-2013, 12:34 PM   #15 (permalink)
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Excellent project and very promising results. Keep up the great work!
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Old 04-14-2013, 11:56 AM   #16 (permalink)
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Two updates...

I solved the rear window issue for $40 - I found a deal on a rear backup camera with a 5" LCD. It mounts perfectly under the rear lip, and I added a quick connect fitting so that it pops off with the cap. Also, I picked up the lights and wiring, and was going to tackle that this weekend. However...

We had some thunderstorms on Wednesday, and apparently my lightweight design was a little too light. We had wind gusts of about 70mph, and one of them spun up directly rearward of the truck. The cap was blown up and over the truck, landed on the hood, destroyed my bug deflector, gouged the paint, and banged up the cap a bit. I now have a hole about the size of a soccer ball on the driver's side of the cap... I'd post pics but at this moment I'm too heartbroken.
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Old 04-15-2013, 07:46 AM   #17 (permalink)
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Two updates...

I solved the rear window issue for $40 - I found a deal on a rear backup camera with a 5" LCD. It mounts perfectly under the rear lip, and I added a quick connect fitting so that it pops off with the cap. Also, I picked up the lights and wiring, and was going to tackle that this weekend. However...

We had some thunderstorms on Wednesday, and apparently my lightweight design was a little too light. We had wind gusts of about 70mph, and one of them spun up directly rearward of the truck. The cap was blown up and over the truck, landed on the hood, destroyed my bug deflector, gouged the paint, and banged up the cap a bit. I now have a hole about the size of a soccer ball on the driver's side of the cap... I'd post pics but at this moment I'm too heartbroken.
That storm damage sucks! Hopefully insurance will help. (fingers crossed)
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Old 04-15-2013, 10:34 AM   #18 (permalink)
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That storm damage sucks! Hopefully insurance will help. (fingers crossed)
Unfortunately, my deductible on comp is $500, but thankfully the damage looks to be less than that. The hood doesn't appear to be dented, just scratched, so I'll be fine with one of those touch-up paint pens for now. I had been contemplating removing the bug deflector anyhow... but now I can't do any ABA testing with/without it installed.
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Old 04-15-2013, 03:29 PM   #19 (permalink)
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Vortec 4.3L v6, NV3500 5-speed, GU4 3.08 rear axle
Remarkable fuel mileage even before the cap was put on.

My 4.3L S-10 4x4 gets only about half that, best seen is about 20 mpg hwy.

Ouch about the thunderstorm, sorry to be reading of it.
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Old 06-26-2017, 12:49 PM   #20 (permalink)
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i realize this is a bit of an old thread, but its the first time ive been able to find anyone who built an aero cap specifically on an s10. how did your mpg gains fair? how well did it hold up to daily driving? how come you had the center of the cap taper down from the height of the sides?

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