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So far as fabrication the only tools used that alot of people wouldn't have is a chop saw, mig welder, sheet metal brake and metal shear.
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No English Wheel, like Ron Covell uses, in that list.
Take a look at these:
Polymetal
MAX-metal HD
Aluminum skinned plastic. Available in 3 and 6mm thickness. The regular Max-Metal can be had one-sided and Max-Metal HD has thicker skins. I hear dirt track racers use it for their wings.
I've experimented with samples of PolyMetal, rolling and braking and shearing it. I suspect it would work on an English Wheel.
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Nice project overall. If you do a next generation, you could put tail-fins on it with a dead-level top edge and have an oval or removable crossbar at the tips to make a complete rectangular rack.
+1 vote for a dropped tailgate extension, but it would need a diffuser underneath. Half your drag is in the wheelwells. I think the aerocap should start at the top of the windshield.