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I just bought my 2014 Volt earlier this year, and I'm in a similar situation. My commute is about 48 miles round trip, and I average about 42 miles per charge. I cringe every time that gas engine comes on with only a mile or two left to go...
How are your pizza wheel covers holding up? Where did you get the expanding plug from? What size? I measured about 1.5" minimum opening, but the inner cavity is larger. Did you take the wheels off and insert the plug from the inside?
I also noticed that the pans look a little too small. I measured a little over 18" to get beyond the lip of the rim. What size are yours?
I've also been looking at hitch mounted cargo boxes. The torque cental invisi hitch seems the most robust and keeps ground clearance, but the boxes I've found will be so high they enter the wind stream. I'd only be using mine on long trips though, not for consistent FE gains.
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