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I used some extra roofing sheet which is a flexible rubber about 3/16ths of an inch thick. I went down 4" to match the suspension components on my Dakota. I then helped support it with a little bit of sheet metal, but I really need to redesign that.
I did all that, along with Royal Purple Gear oil in the rear, and full synthetic change of the transmission... and then started going to a different job so i wasn't able to properly test a difference in economy. I don't think it was a huge difference though... sadly.
Also, instead of using 1/4" ply for your bellyban stuff, coro-plast, or the plastic cardboard stuff that signs are made of, would be a LOT better. Lighter and just as strong.
Also, think about a grill block. I plan on doing that next and see if it works any better since when the weather bumped up, I went from 14 to 17 mpg with no change other than getting a few extra tools out of the back.
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