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Old 07-23-2014, 10:35 AM   #2 (permalink)
BamZipPow
T-100 Road Warrior
 
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Join Date: Apr 2008
Location: The Woodlands, TX
Posts: 1,902

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 current (2019) - '98 Toyota T-100 SR5

BZP T-100 (2020) - '98 Toyota T-100 SR5
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My current version of my aero cap is skinned with Foamular with a wood frame. You might want to try a few designs in in plywood or even Coroplast before embarking in Lexan or acrylic. Acrylic is prone to shattering/fracturing/cracking when stressed or impacted. Lexan can handle impacts to a higher degree. Lexan is more expensive than acrylic. UV light will eventually cloud Lexan or acrylic over time. UV coatings can extend the clarity of Lexan or acrylic.

If you do a lot of stop and go, you may not see a major improvement in yer gas mileage with an aero cap.
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