Using cloth+epoxy for aerodynamics!!
 

I'm planning on using some cheap bed sheets to make a aero camper shell for my s10 and a aerodynamic belly pan by pulling a plastic sheet tight under the truck, then pull the sheets tight over that and coat the whole thing with a few layers of epoxy to stiffen it up!! That way its removable and also doesn't wave in the wind reducing aerodynamics!!

How many layers of bed sheets? How will it be removable?

You might stretch the sheets, then add twine or yarn that you can pull tight to pre-tension it. Then add the epoxy.

I'd suggest a fabric with a bit of stretch to it, if you want to avoid wrinkles.

And, maybe make it upside-down, because gravity will make it concave if you do it the right way up. I suppose some air pressure on the inside would make it convex as well.

I'm planning on doing 2-3 layers, and using tarp clamps to pull the sheets as tight as I can. The first one I'm planning on making is the belly pan so I'll see about getting some pics of my setup when I do it. The belly of my s10 is pretty straight so I don't think I have to worry about the angle of the sheets too much.

I'm looking forward to seeing this.

I use 1" hex mesh wire fencing bonded between 5 mil plastic tarp material with contact cement. No mixing needed and plenty cheap.

I'd like to see an example of that. If you slump-molded the three layers into a compound curve and then turn it over, how much weight would it be able to take?

http://i1187.photobucket.com/albums/...neinterior.jpgThe mesh is easily formed by hand and I use plastic tubing for ribs.

Polypropylene or polyethylene? How would you characterize the strength? Do you think two layers of wire mesh would be any improvement?

With polyethylene it might be possible to fuse the layers with a heat gun and dispense with the contact cement.

I tried multiple layers but didn't get good adhesion. For thicker wire go for wider spacing. Not sure of plastic as I used scrap covering plywood for shipment. Check the tarps at the farm stores. I roll a spare tire over the layers to get best results.