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Old 11-26-2008, 08:38 PM   #43 (permalink)
orange4boy
Master EcoModder
 
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Join Date: Aug 2008
Location: The Wet Coast, Kanuckistan.
Posts: 1,275

The Golden Egg - '93 Toyota Previa DX
90 day: 31.91 mpg (US)

Chewie - '03 Toyota Prius
90 day: 57 mpg (US)

The Spaceship - '00 Honda Insight
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I built the aluminum sandwhich of two pieces with the coro between bent to the shape of the bumper using a fencepost as an bending brace. I got the two pieces bent as close together as possible then I pre drilled the front bar holes and countersunk them, then clamped the two in the center, added more clamps and drilled the pilot holes through the back barand coro, tapped them with a spiral tap on a cordless drill and put in the 8-32 flat head stainless hex socket screws. The moved around the sides like that.

This make a rigid structure that requires less attachment points and no under support to the vehicle. I will add a strip along the top as it's a littile flimsy right now with only 4 screws holding it on top plus one on each end.

You will have to be creative with your set up. the tricky part will be the wheel well attachment but perhaps you can get away without it if you can attach to the bumper there.

The aluminum was about $18 for a 20 footer.
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