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Modding an 02 Ford F250
My brother owns a 2002 Ford F250 work truck with 4WD, 7.3 diesel, and manual transmission. Photos of his truck showing the grille block and aero topper are in my profile. He has fuel consumption records since he bought the truck over two years ago. He lives on southern Wisconsin. His MPG varies about 10% from winter to summer, and the annual average is very close to the MPG at 40 deg F.
He averaged about 19.5 MPG back when he first bought the truck, with driving style described as “sorta DWL”. He then bought a Scangauge and used the Scangauge to learn how to really DWL A grille block was also installed. His mileage increased to 21.5. Another driver drove the truck at this time, and got 18.7 MPG. That driver had extensive experience driving semis.
The upper grille block is the window film sold in hardware stores for covering house windows. It typically lasts until he drives through tall brush and pokes holes in it. The lower grille block was molded in place with a plastic bag filled with foam in a can. The upper grille block stays in place year around, the lower block is removed when the temperature is above 50 deg F.
The aero topper has been on the truck since the middle of last summer. Average MPG with the topper is 23.5, slightly lower in winter and higher in summer. Head- and tail-winds also affect the MPG. He expects about 25 MPG on a good warm summer day. The topper is lockable, and blocks the tailgate closed when locked. The triangular shaped side panels are hinged on top for side access to the box. They are self locking in the closed position when the topper lid is closed. His calculations for the gas lift struts were off slightly – they only hold the top up at temperatures over 50 deg F. The hinged portion of the top has 2 X 4 ribs covered with 9/16” plywood. It is painted with flat gray house paint.
Because none of the changes were tested for exactly one year, the MPG's are his best estimate based on the average temperatures for the period tested. This is ABC testing, so part of the recent MPG improvements may be from better driving.
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