Fuel Economy, Hypermiling, EcoModding News and Forum - EcoModder.com - View Single Post - My T-100 grill blocks over the past few years...

BamZipPow · 08-02-2012, 12:42 PM

Here's quick photo history of my grill blocks...

Grill block using Coroplast shutters (one closed)

Grill block using Coroplast shutters (both closed)

Grill block (open) using Coroplast shutters (painted black) and tape

Abandoned the Coroplast shutters as the tape failed over time and I didn't have a good way of securing the shutters at the pivot point.

With my new T-100, I started out using pipe foam insulation. Just ziptied in place. Found out the foam shrinks over time when exposed to the sun and engine heat. Reinforced the center with PVC Schedule 40 pipe. Foam insulation breaks down over time due to the environment...

Grill block using foam pipe insulation (33%)

Grill block using foam pipe insulation (67%)

First iteration of the Coroplast grill block (67%) taped in place. Gorilla tape eventually started pulling off over time.

First iteration of the aluminum grill block (67%) taped in place. Duct tape eventually started pulling off over time.

Last iteration of the aluminum grill block (67%) screwed in place. I used 1" PVC PE200 pipe fer the backing support.

Since pulling the aluminum grill block since it was gitting pretty hot here, I only had the top 1" PVC tube doing grill block duties. So I went and custom cut a new tube and painted it black. Ziptied it to the grill. Seems to be a winner...

I didn't use Schedule 40 PVC...I used the PE200 since it's thin walled and easier to shape/work with. I ground the ends to shape by rubbing it against the cement road...

33% grill block...wide view.

Close up view...

08-02-2012, 12:42 PM	#1 (permalink)
BamZipPow T-100 Road Warrior Join Date: Apr 2008 Location: The Woodlands, TX Posts: 1,921 BZP T-100 (2010) - '98 Toyota T-100 ext cab - 3.4L/auto SR5 Last 3: 24 mpg (US) BZP T-100 (2011) - '98 Toyota T-100 ext cab - 3.4L/auto SR5 Last 3: 23.66 mpg (US) BZP T-100 (2009) - '98 Toyota T-100 ext cab - 3.4L/auto SR5 Last 3: 19.01 mpg (US) BZP T-100 (2012) - '98 Toyota T-100 ext cab - 3.4L/auto SR5 Last 3: 25.45 mpg (US) BZP T-100 (2013) - '98 Toyota T-100 SR5 Last 3: 25.79 mpg (US) BZP T-100 (2014) - '98 Toyota T-100 SR5 Last 3: 23.18 mpg (US) BZP T-100 (2015) - '98 Toyota T-100 SR5 Last 3: 23.85 mpg (US) BZP T-100 (2016) - '98 Toyota T-100 SR5 Last 3: 17.62 mpg (US) BZP T-100 (2017) - '98 Toyota T-100 SR5 90 day: 20.78 mpg (US) BZP T-100 (2018) - '98 Toyota T-100 SR5 90 day: 20.19 mpg (US) BZP T-100 (2019) - '98 Toyota T-100 SR5 BZP T-100 (2020) - '98 Toyota T-100 SR5 2012 Scion iQ - '12 Scion iQ Base Thanks: 3,502 Thanked 1,395 Times in 968 Posts	My T-100 grill blocks over the past few years... Here's quick photo history of my grill blocks... Grill block using Coroplast shutters (one closed) Grill block using Coroplast shutters (both closed) Grill block (open) using Coroplast shutters (painted black) and tape Abandoned the Coroplast shutters as the tape failed over time and I didn't have a good way of securing the shutters at the pivot point. With my new T-100, I started out using pipe foam insulation. Just ziptied in place. Found out the foam shrinks over time when exposed to the sun and engine heat. Reinforced the center with PVC Schedule 40 pipe. Foam insulation breaks down over time due to the environment... Grill block using foam pipe insulation (33%) Grill block using foam pipe insulation (67%) First iteration of the Coroplast grill block (67%) taped in place. Gorilla tape eventually started pulling off over time. First iteration of the aluminum grill block (67%) taped in place. Duct tape eventually started pulling off over time. Last iteration of the aluminum grill block (67%) screwed in place. I used 1" PVC PE200 pipe fer the backing support. Since pulling the aluminum grill block since it was gitting pretty hot here, I only had the top 1" PVC tube doing grill block duties. So I went and custom cut a new tube and painted it black. Ziptied it to the grill. Seems to be a winner... I didn't use Schedule 40 PVC...I used the PE200 since it's thin walled and easier to shape/work with. I ground the ends to shape by rubbing it against the cement road... 33% grill block...wide view. Close up view... __________________ Dark Aero-The world's first aerodynamic single wheel boat tail!