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Sven7,
You must be a student at CCS. I have worked with many graduates from there. Good Trans program. You are very right about heavy truck manufacturers only redesigning the nose of an existing truck for aero. The costs are way high for a complete redesign as you state. I have done alot of work in the Peterbilt Motors design studio. We did a series of aerodynamic trucks in scale model form. The wild stuff was rejected.
I may well be up in your neck of the woods working at Ford in Dearborn soon. Good luck to you in your studies and I am sure there will be a job for you in the industry. You may have to be patient but it will come.
Bondo
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