Awesome work so far! I hope to fashion an aero cap before too long. I think that will prolly be my biggest fuel saving mod, other than my Scan Gauge.
You said you were considering an air dam, but if you are planning to off road your vehicle, wouldn't skid plates work a little better for you. They may clean up the belly of your vehicle and have the added benefit of protecting your underside from those pesky rocks and stumps. Any gaps in the plates could possibly be bridged with coroplast or some kind of filler material. The plates would prolly be a lot more expensive than a home-made air dam, but it would be a justifiable cost if they protect your transfer case and stuff from being punctured. Just a thought...
__________________
|