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I'm planning an aluminum aerocap for my 2004 Dodge Dakota. Aluminum sheet is strong, light, easy to shape and fasten with ordinary tools, weatherproof, doesn't need filling and painting, and looks way cool.
The idea is to make it in three sections - two triangular side panels permanently attached, and a removable centre panel. The side panels will have a slight curve to match the sides of the cab and to prevent flapping. The large centre section will we curved to match the roof, and sloped around the magic 11 degree mark. Light aluminum angle along panel edges will add strength and provide attaching and mating surfaces. One nicely shaped wooden former against the cab should be the only non-aluminum part.
In theory, should be piece o' cake. In practice...
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