A Quest for 35mpg (Subaru Outback Limited Sedan 2.5L auto)

[Zerohour]

Pictures from tonight, my Contour, and some of my sketches (sorry cell phoned the sketches, don't have a scanner).





Had just enough fiberglass matte to get one solid piece. Its rather thin, and since it needs to be impact resistant, I'll need to run and buy more in the morning. But it can cure overnight.

Contour:


My sketches:

Okay traced that one lol



Current Aero Projects have been given proper ridiculous acronyms as well:
FWAD - Front Wheel Air Deflectors
FABB - Forward Air Bumper Block
FUBAD - Forward Under Body Air Deflector

:laugh:

[Zerohour]

Progress made this weekend:






Air intake setup:

[skyl4rk]

If you are looking for BIG aero gains, think about a boattail.

[Zerohour]

Air goes over the front before it passes out the back. :-) Maybe with time. I have a few other aeros to do up front first. Then I'll start playing with the exit ways

[2win2rbo]

Nice work Zerohour! We have the same quest (35 mpg) but I am currently travelling just around a very hilly city. I am about to do the belly pan mod.

[Zerohour]

So just to throw out an update: Working on surface quality. I'm trying to keep the weight down, so I won't be filling in the layers with bondo/bondo-glass. I"m sticking to smoothing it with resin, and thinning it down each time. So its fill, dry, sand, clean, glass. Slow work to say the least.

If nothing else I may just take them as they are by the weekending and mount up and go for the coming week.

Working on 3 pieces, little air deflectors for the wheels, and the front bumper block. All three may be on the weekend...*crosses fingers*

[RobertSmalls]

Fairing compound is like a dust composed of plastic microballoons. Add it to your resin to make a lightweight paste that hides surface asperities and sands easily. I love that stuff.

[Zerohour]

Working in the Garage today, hoping to be spraying some paint this afternoon.

[Zerohour]

Update: Fat man + Tyvex Suit + Warm = Lame

ugh chugging along on this project, but I might just kill me!

[mcrews]

you have a nice ride.
And you really are taking a nice comprehensive approach to the whole process.

On my 02Q45 .... 58mph is a sweet spot. After mods I can get 30plus mpg all day with the cruise control (epa 23). I know sometimes you just have to get there and you gotta go fast.
I run a 255/45/18 on factory rims. the factory size was 245/45/18. it's worth about 3.4% greater diameter which inturn lowers the rpm at cruise. I do alot of freeway driving about 75% of my 35-42k a yr. you might give it a look.