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Hey Brent,
I think you should definately go with an "aero-cap" for the long run. Just make sure to keep it light weight.
Right now I have been running without any cap, and I got 30.1 mpg on my last tank.
I experimented with a modified tonneau cover made from contruction plastic stretched over the cab and bed. It think it helped a bit, but really needed a frame underneith to shape it better. (I still have packaging tape all over my truck!)
I also took a shot at building an aerocap with wood framing and greenhouse glazing material. I am not much of a carpenter and couldn't get all the angles right, and abandoned that.
I think the best way to make a cap would be using 4x8 foot shower wall panels, heated and bent around a LIGHTWIEGHT frame. There was one on this forum done that way over PVC pipe that looked really nice.
I say lightweight because I think weight was an issue with the standard cap I have. That square cap really cut into my fuel economy. I could always feel it catching the crosswind, and that thick fiberglass is just plain heavy!
Does anyone work at a place that makes things in giant plastic molds? Would be great if we could just stamp out big, cheap aerodynamic truck caps!!!!!
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