1st Gen Toyota Tundra Aeroshell Build

[Macskyver]

Today I started the installation step. I basically have the shell bolted down and the front window installed. After looking at things, I am a little torn how I want to set up the bed inside. I was originally thinking of making a platform that sits above wheel well level. That case would fit a full size mattress with storage underneath. Now I am thinking I want to have the bed as low as possible, go with a narrower three quarter size mattress (6" narrower than full), and have storage on the sides. I am heavily leaning toward the latter idea. This way I can access storage much easier and have the ability to sit comfortably with my head straight up. Tomorrow I will try to finish up the rear window.

[KamperBob]

Looking good!

FYI, attaching pic showing how a mod to a previous truck/topper for better usability. It was a Tacoma so only 6' bed and narrower box. Two adults slept on the bed floor using thin cushions (camp pads) that stowed easily between sleeps. Maybe not your solution - just trying to fuel your brainstorm.

[Macskyver]

Originally Posted by KamperBob

Looking good!

FYI, attaching pic showing how a mod to a previous truck/topper for better usability. It was a Tacoma so only 6' bed and narrower box. Two adults slept on the bed floor using thin cushions (camp pads) that stowed easily between sleeps. Maybe not your solution - just trying to fuel your brainstorm.

Thanks.

That's a cool idea, thanks for sharing. In my case, I'll be storing a bunch of heavy/awkward recovery gear (like shovels, handyman jack, tire chains, etc.), so I think side storage boxes may work a little better at keeping that stuff segregated/contained. I still like that shelf idea though.

[Macskyver]

Over the weekend I got a lot done on the rear window. Here are the wing windows with supports:



Here is the almost complete rear window assembly:



Here are some more views of the shell with completed exterior:





I still have to make the air spring assist for the rear window, so there are a couple aluminum brackets to design plus installation left on that. I also need to install the bug screens for the vents. After that, the shell will be done. Then I can move to the interior storage/ sleeping area.

[BamZipPow]

Very sharp!

If I recall correctly, yer aero cap should fit my T-100 as well.

[freebeard]

Congrats.

So the 'wind wings' are fixed and the latches are for the center liftgate? What are the aluminum plates under the windwings — gusset plates?

[Joggernot]

That is the nicest areocap ever. Thanks for taking us through your build to this point.

[ctmaybury@yahoo.com]

Looks beautiful. Can't wait for highyway mpg report.

[NeilBlanchard]

Stunning work!

Do you plan on tuft testing it?

[Macskyver]

Originally Posted by freebeard

Congrats.

So the 'wind wings' are fixed and the latches are for the center liftgate? What are the aluminum plates under the windwings — gusset plates?

You are correct. The key latches hold the center window closed. The aluminum supports on the wing windows are purely for structure. Without them, the rear windows would be pretty flimsy and a person could easily pull the rear window open even when locked.