Hi all,
Inspired by the aerocap threads here on ecomodder, I have been encouraged to build my own and report fully on my design and construction experiences here.
Over the next couple of months I'll be posting full construction details, with detailed photographs, and afterwards, if anyone wants to copy my design (which is, to be fair, somewhat inspired by Bondo's fantastic design, but is constructed very differently) I will even mail out templates on paper to anyone who asks.
My design will have a light wood frame, covered in strips of 1/4" plywood to make the shape, then covered in fiberglass and bondo to get a great finish. I'll then finish paint it to match my truck.
The design will have an opening lid section, and will be insulated on the inside.
So far, the only mod I have done is a fan/shroud delete, replaced with an electric thermostat and two 16" e-fans. This has bought me a small gain in FE, mostly with cold starts and in town driving, where I get around 1.5mpg improvement. From here on I'll enter details on the site, since I am no de-lurking
If anyone has any questions, suggestions or support, I'm all ears
Dave in Austin