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Here is the rough design I have come up with so far for the bumper. Many parts of this design are rendered as simple curves, but in reality would be complex curves. Note a few design features that may not be apparent through the sketch:
The “bumper” (bottom part) will be angled back slightly; to direct airflow both up and to the sides of the vehicle. The flat section between the curve of the lower bumper and the base of the grill/light covers will be rubber or other material.
The “grill cover” (top middle) bent tube part will install in front of the existing grill, and the vertical bars will be tracks, allowing panels to come out of the bottom part of the bumper and block off the grill. I am thinking this part will be pneumatically actuated from inside the truck, and will have two sections, each independently controlled. That way I can have open, halfway, and closed settings.
The light covers (top outside) sections are not rendered well on this drawing, but will be smaller bent tube, except covered in Plexiglas or similar to direct airflow around the truck. They will basically be a cover for the existing lights and fit very close to the bodywork.
For all of the parts on the upper half, I will use rubber or similar material to have a smooth transition between the bumper and existing bodywork.
Imperfections I know exist in the design:
There is the step between the lower bumper and the upper grill and light covers. This is part of my crumple zone system. I put a radius on the top of the bumper. Would it help to radius (Concave) between the flat bottom and the grill/light covers?
The grill cover is currently rendered as a flat piece. I would like this piece to be slightly curved, however since I am making this part actuated, I am not yet sure if I can curve it and make it operate well and still recess into the lower bumper section. The grill cover is rendered as a 100% grill block, however I wouldn’t want to cover the entire thing, so I don’t know if it would be better to try to make it fit flush with the sides and cut in vent holes, or just make the grill block stay away from the sides and let that be the gaps. I am figuring on roughly 15% free area as compared to the radiator when the grill block is fully closed. My understanding is that the best design on this would be to have the opening as a thin slit running horizontally across the base of the grill block, as compared to the vertical openings that would be present if I leave a gap on the sides.
So, anyone have any thoughts or ideas?
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