[Big Dave]

rdefayette:

Many people here use plastic materials and I even used plywood and rubber matting on a aerocap, but metal bespeaks quality,workmanship and durability.

If you do a Gen II, I have some suggestions.

1. Make it out of aluminum. In hilly country weight matters. Here on the frozen steppes of Indiana, the terrain is super-flat and weight matters little, but you are never on level grade, I suspect. The "grade/load" of the road load equation is your enemy, particularly in light of the speed-limiting terrain. The racer's problem (getting that last 20 pounds of weight off) is certainly true, particularly in that a pickup driver doesn't know what kinds ogf load he'll have top carry tomorrow.

2. Don't try to hit the top rail of your tailgate. that seems to be the intuitive goal but the well-tested "template" says crossing the tailgate about 8 inches above the top of the tailgate will give you better aerodynamic effect and gain you some cargo space in the bed.

3. Crosswinds will not much affect your driving, but BE SURE to fasten it securely to the bed. Bolts good. C-Clamps unreliable. Ask me how I know. I thought my flat tonneau was down securely with six C-Clamps but a March gust got a grip and I wound up chasing the tonneau cover fifty yards into a muddy cornfield. Make sure your hinges and latches are teenager-proof.

4. Keep your fingers out of the English wheel.