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91 Dodge airocap
This is my prototype airocap
Attachment 17595 making my rain drop Truck is a 91 Dodge D250. 2wd 3/4t A less than150lbs for complete airocap and headache rack I used 12mill boat shrink wrap for my prototype covering http://pages.ebay.com/motors/link/?n...363918&alt=web $169 usd shipped for 10 ft x40ft this thickness is only available 40ft wide by $10usd per ft. Thinner, cheaper, narrower shrink wraps are available, other cover options are ortex600, ortex6000, aircraft fabric, or regular canvas as well many others. I went with shrink wrap for quick repeatable and smooth and cheep prototype. for the aircraft fabric and ortex they require special adhesive to attach. Ortex600 is my choice for my final covering and canvas would be flapy and heavy after waterproofing Attachment 17594 the canapé can be removed for aquard load or simply closed on the load.switch leaves the headache rack with its taper from cab width to mid bed rail . The steel frame can support aprox. 180lbs (me) hanging in the center. Can you say snow load Attachment 17597 Attachment 17596 I set the rear defuser at approximately 10" past to clear the tailgate for opening and closing without opening the cap |
Awesome has happened when you aero mod a 1st gen Dodge with a 12 Valve :D
None of your pictures came up, and the links are dead? If you will, upload them to a photo database such as Photobucket or Postimage.org Copy the direct link and paste in the box after clicking the "Insert Image" button. It is yellow with a mountain on it. Hit Enter and the picture should be in the reply for you to post. |
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That is different! I dig the boat wrap you used, that was something no one has thought of yet to my knowledge.
Any mileage increases to speak of? |
better mileage
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first tank was above my average (2nd best) wile loaded 5520 tair 7160 gross with dirty air 22.6 fuel fill dated 05/ 05/ 15 up the Columbia river gorge . As compared with 01/09/15 fill 20.06 mpg going the other way.
2nd tank same load 550el to 5600el 22.22 up contanental divide dated 05/07/15 compared with down @23.01 Conclusion yes it worked despite a load and not able to close all the way |
oratex 600 light weight oratex 6000 going through FAA approval process
My easy compound curve fabric for after prototyping
Oratex Specifications and Technical Data Oratex6000 Material: Modified polyester Material thickness: Approx. 170 µm (.0067 in.) Weight: Approx. 140 to 160 g/m² (0.459 – 0.524 oz/ft²) Tensile strength lengthwise: Min. 1300 – 1600 N/50 mm Tensile strength crosswise: Min. 1100 – 1400 N/50 mm Breaking extension lengthwise: 12 – 20% Breaking extension crosswise: 12 – 20% Tear propagation load lengthwise: 26 – 32 N Tear propagation load crosswise: 28 – 34 N Burst strength: > 1000 kPa (> 145 psi) Burst elevation: > 15 mm (> 0.59 in) Shrinkage lengthwise: 9 – 13% Shrinkage crosswise: 8 – 12% Flammability: Not flammable after application to airframe Melting point: 250°C (482°F) Air permeability: Airtight Other characteristics: Fuel resistant, can be painted Oratex600 Material: Modified polyester Material thickness: Approx. 120 µm (.0047 in.) Weight: Approx. 92 – 122 g/m² (0.301 – 0.4 oz/ft²) Tensile strength lengthwise: 750 – 1050 N/50 mm Tensile strength crosswise: 650 – 950 N/50 mm Breaking extension lengthwise: 10 – 18% Breaking extension crosswise: 11 – 20% Tear propagation load lengthwise: 18 – 24 N Tear propagation load crosswise: 16 – 22 N Burst strength: 500 – 700 kPa (73 – 102 psi) Burst elevation: Approx. 14 – 18 mm (0.55 – 0.71 in) Shrinkage lengthwise: (338°F) 8 – 12% (reference temperature 170°C) Shrinkage crosswise: (338°F) 8 – 12% (reference temperature 170°C) Flammability: Not flammable after application to airframe Melting point: 250°C (482°F) Air permeability: Airtight Other characteristics: Fuel resistant, can be painted |
That's an interesting material. How did you fasten it to it's framework? Staples?
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The shrink wrap is heated to almost melting pointand it sticks to it self[edit add :as compared to the oratex is put on with a heat activated glue to it self or your frame of choice
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'tair' = tare
el = elevation 'fule' = fuel |
Deejaaa
Gumby nickname from high school next question Better mpg? answer: yes explanation of how I got said answer I got #2and3 top mpg for lifetime fuel log driving 880miles@60-65 for 2 tanks of fuel hear are pic of dirty air on a airocap https://plus.google.com/+daviddroesc...ts/1a2i9KkArPz loaded 5520 tair7160 gross 7160# gross = truck + passengers + load +fule (per Or state DOT scale) -5520# tare = me + truck full tank fuel (per WA state DOT scale ) -------- 1560# cargo 550el to 5600el 22.22 up continental divide dated 05/07/15 compared with down @23.01 https://plus.google.com/+daviddroesc...ts/JH9BGv9jRqe compared with down @23.01 west bound going home in jan 5 months ago. life time best dropping down "the continental divide ( highest place in America) to sea level |
Just be careful of how long the material will last. While the shrink wrap has some UV protection, it's not rated fer the wind loads and temps over time that you will be subjecting it to on the road. You will need to inspect it carefully each time you go out and know that as you approach the 6 month mark, it may need to be replaced. I have some reservations of the material lasting more than a year. ;)
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With any luck by 1 year in I will he happy with my shapes and can spend $76.95usd Approximately 1 yd² / linear meter for the material in post#6 $76.95 USD ORATEX 6000 . ORATEX 600 @$54.95 Approximately 1 yd² / linear meter +shiping from Germany. as well as a small list of consumables.
Website Oratex: The Better Aircraft Fabric |
i'm surprised it weighs 150lbs. is the frame steel rod?
i like your idea and will keep this in mind. i imagine i could make a frame and use that material to make a kammback. lightweight and easy to use. plus my car is white. when it's heated, will it only stick to itself or would it also stick to a painted surface? |
Deejaaaa
it is melted to gether (thermal welding) I used a mini torch to spot weld then heat gun to finish the seem after that grass torch to shrink yes it only sticks to it self not paint The ORATEX uses special adhesive similar toPiper J-3 Cub aircraft |
Deejaaaa
as for weight this is designed as two parts. A standalone headache rack capable as any on a ranch truck. With an airodinamic twist (the sides of the headache rack are tapered and only 15 □" of added frontal area) headache rack~40-60lbs: 1"x3" .065 steel with 3/8 plexiglass 20"x20" cutout for the pass through window canapé ~35 lbs :1/2"id .065" tube for sparse 5@ 9' +~20' for cross bracing and tail extension radius + 1"x1" .065 square 30' for frame + 50 3"x3" .065 corner gussets. The canapé can support my 190lbs (tested on shop floor before covering lol). The final product will be able to be raised and locked up as a wing for towing an enclosed trailer (as most Comercial units camper or box have a flat front ) ever tow a box trailer with a VW Bug not easy Bang zip pow Check out about the oratex https://youtu.be/GJ-KHRHlRDg |
¿what is the improvements?
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Well!! action speaks louder than words.
Attachment 18182 This comparison is the info in my fule log from Dec 31,2014 through June 20,2015 1st 6 months of ownership 1991 Dodge D 250 first gen cummins LE Gas Mileage (little jona) - EcoModder.com Bone stock as dodge buld it. 2501mi 137.140 Gal. 46+ oz CETANE booster =18.237 mpga ( miles per gallon average) in all conditions, loads, weather, grades, and speeds This includes exost wrap (not stock) VS Airocap with all stock w/exost wrap 5062mi 219.451Gal. 75+oz CETANE booster = 23.067 mpga ( miles per gallon average) in all conditions, loads, weather, grades, and speeds Lifetime Fuel Economy: 22.3 mpg (US), 10.5 L/100 km, 26.8 mpg (Imp) 90-day Fuel Ec I am planning an ABAB TEST later this summer however wile on the road. The canapé is not ssomething that I should leave tied to a tree till I get back past that part of the country. |
The comparison of fuel economy if I strike the two highest and the two lowest is 20. 5 22 miles per gallon average stock
VS 23.6 26 miles per gallon average w/ the airocap |
Update 6months
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While in Las Vegas NV temps were geting over110°f and the plastic relaxed Slightly about 1/4" so I used some "light"tan hammer tone plastic compatible rattle can paint. Painted over the wight duct tape burn hole patches. Figured it would help as sunscreen spf 100. Maby. However much ro my dismay it turned out a dark copper. So during my 2nd trip to LV the heat sag was much larger problem @ about 117°f it would sag about .5" on the 2 center spans at the hottest part of the day. But the plastics would go back to tight after about 1-5min of driving got back to the soggy cool NWand it was back to a snear drum.
Attachment 19345 BamZipPow you called it 6months. However the Oratex has been tested past 10years passing FAA testing so it will work for the long hual. Srick and shrink repairable easy compound curves Hear is a hammer test with the Oratex I found. http://https://youtu.be/yoI5PEIxtEg Attachment 19344 Well 6 months in I saw 3/4" crack form in week spots only(over heated cussing it to thin after thickening) Attachment 19346 tube from a 4 in. fat tire bike as a gap filler May up to pool noodles I didnt account for rhe forward lean of the back of the cab v2.0 will. The last 2 are learning curve errors paint chiped off from improper attachment Attachment 19342 The missing paint(bright spots) was caused by the bace plastic changing to much strechmarks given time theas would become cracks justified an extra 10# of steal fraim work wasn't melted well enough and separated nextto hot Attachment 19343 Changes for v1.2 Added 1/2" Millar backed fome between the fraim and plastic. It softened the allmity side to top transition and noise suppression Added an inner hoop for mounting point. Added lift struts. Added a latch mechanism Added Garage goor seal for bededge seal Total weight for moving part is 35# V1.0 was 21# |
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Attachment 19634Attachment 19623
Had 4" of power fall and decided to do an air flow test these were taken after 2mi at 25 mph and 1mi at 45mph out side Anaconda, MT Attachment 19625 notice the vortex patterns at the transition from horizontal to vertical Attachment 19626 I only cleared the snow from the windshield, side windows and hood Attachment 19628 Attachment 19627 these were taken near Wisdom, MT 10mi at 60mph the first one shows the air attachment going to the tail in the horizontal plain and warping in in the back from vertical Attachment 19624 Attachment 19628 Attachment 19631 a small disturbance behind the hinge other wise it looks like the "ladder rack" [part that protrudes above the cab ] dues not create much disturbance , as expected some but small. the air is steal able to stay attached Attachment 19630 these were taken at Georgetown lake speeds of up to 70mph Attachment 19629 this shows the termination past the tailgate after I built the canape I noticed that "ALL" the new trucked have a similar shape added to the top of the tailgate depending on the make from 2"-6" to help brake the vacuum bubble at the tailgate Attachment 19633 and to show why a 2 piece canape. It's a truck its gotto be able to work. 30 70lbs bails of hay Attachment 19632 so far I'm avraging 24mpgs on the flats with a 22mpg low and 27.9mpg all time high |
CdA/gas/diesel mpg
I got into Hucho's book and located the material I mentioned.It wasn't what I thought.
It had to do with the EPA Composite Cycle: *Lowering drag from Cd 0.46,to Cd 0.30 (a 34.78% drag reduction) would provide: *a 14% fuel consumption reduction for a gasoline vehicle. *a 17% '' for a Diesel vehicle. -------------------------------------------------------------------------- *It doesn't parse out a steady-speed,level road relationship. *And it has more to do with the higher thermal efficiency of the Diesel in Urban driving than aerodynamic effects on the highway. -------------------------------------------------------------------------- *We might default to the earlier GM metric of a 5% mpg improvement for any 10% drag reduction at 55-mph. *And a 6% mpg improvement for any 10% drag reduction at 70-mph. -------------------------------------------------------------------------- *The aerodynamic fraction of total load/power does increase with velocity,but as the drag comes lower and lower,there is a diminishing return. -------------------------------------------------------------------------- *What we're interested in,is the reduced power load,which directly affects mpg,based upon a constant BSFC for the engine which undergoes gear-matching to keep the new top speed rpm equal to the non-streamlined top speed rpm.Without gear-matching,we can lose up to 50% of the streamlining benefit,as the engine falls into an island of inefficient operation. -------------------------------------------------------------------------- *This makes it very difficult to predict things when we're not presented with a BSFC map for our vehicle's engine. -------------------------------------------------------------------------- *And this is aggravated by the fact that even if we get a top speed from say CAR and Driver,Road &Track,etc.,it won't actually represent the vehicle's actual potential,since top speeds are gear-limited perhaps in mid-gear,with 2-additional overdrive gears provided to slow the engine, at a constant top speed (at sometimes,much lower horsepower than rated power,but full torque),to reduce engine wear. :( |
Sorry I missed this before now. Too many hours and days on the road. Will be looking to see how it works out. And the spell checker cracks me up.
As to BSFC map,'check Diesel Daves comments. Nearly any automotive diesel is close for GP work. The VW TDI, for instance. The rest is more intuitive, granted, but there is room to mess around at or barely above 60-mph in terms of gearing. Above 65 (which doesn't save time) the increased wear on tires and the decrease in braking/handling safety closes the door to that. My impression after nine years is that the truck is set to do its best work from 55-65/mph (on my third gen). Really, 58-63 with my gears and trans ratios. This is where to look. |
Tuft testing
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14.51mpg at 80-102mph with Aero Tonto cover.
Had the worst FE ever to day.
From fuel log: Had to run to the ER 90-102mph for 72mi 33mi at 65mp Ran 8-900Egt. 750 on 7%down grade to maintain 90-102mph Pulled to 1100EGT on 7%up grade at 80. Had to stay below 98%throttle to stay in OD dam truck would lose 5-15 mph instantaneously on a down shift as I back pedaled to try and cetch 4th. 14.51mpg Alls well sliped wile sharpening mu chainsaw. Wouldhave been 5-8 stitchesbut alass thanks to Durmabond (aka food grade supper glue) none.and no tendons. should be 25-29mpg going home.at 60-65. |
hate that. i've had my share of cuts and none i'd like to repeat.
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I have moved my average stock 29xxmi at 18.237mpg .to 23mpg with my Aero Tonto cover. (My new name as it dusen't fit the cap description, non opening) this improvement is including a move to Montana from Portland, OR +2 round trips, high speed, normal, loaded, mostly empty, several 1xxxmi with 1200lbs of tools(including rollaway tool box +tools) in the back under the Tonto waiting for my house to close.
9896mi@22.7 (it dropped my average by.3mpg to drive 80-102mph for 72mi) I'll try to recover some of that when home bound tomarow. Decided to spend the night and weight for Costco to open in the morning as they have my motor oil for 38$$/3gal. As compaired to $5/qt. 10,000mi jun1-September 30,2016 4482mi in the month of September alone.saved 102$$in 3 months. Plans are a go for DARCO wind tunnel with Aerohead in September so we all get to see if the air moves as I see it . Won't get an accurate CDa number. As my small full size truck (compaired to todays 3/4 ,1ton trucks) has just a little bit more frontal area than is ideal for the test section. I had a conversation with DARCO back in March and they said no go to big . During one of Aerohead's calls he talked to the staff about squeezing the Wale in . Well the answer was yes with one caveat . Because of % blockage in the test section we would not get CDa pinned down but an ABA is doable. Would like to reskin the Tonto as a few spots reacted badly to the mylars slightly lower melting point and the foam boards lower yet melt point. Causing dimples as the foam shrank/ bonding/ pulling the heat shrink, making the skin and foam bord 1 pice in many places. Cant be to adverse as I've seen 29.3mpg as a high compaired with23.01mpg naked Dreem big chisel down to reality. DARCO was a big dream now its reality. 9.25 days till DARCO getting excited. Ps maby we can answer the old A/C or window down questions. Time for sleep. |
Well sleep is not forthcoming...so
Future plans are... After the dust settles from DARCO. I'll be working on more aero modds the goal is 40mpg before messing with the factory sealed Injection pump ( this is a fully macanical diesel) I may try to put a 12^cm wastegated exhaust housing on my H1C turbo-charger from a HX35 . Stock was 21^cm when I rebuilt the H1C(at about 250,000miat 280,095now) I added a 16^cm housing +exhaust wrap on manifold/ turbo as well as a turbo blanket. The 16and wrap improved efficiency of the motor as it took 100°f less waste heat to spool any given psi.(100°f drop across the boord. Aka 600°f =1psi stock 500° f =1psi modded ect ect) --- I have some led trailer lights so maby a tail cone to accentuate the Aero Tonto cover. ----- I am 6'3" tall so my head is just below the roof , my line of sight is in the upper 1/3 of the wind screen . This was a problem with my 79 Chevrolet pu 4x4 back just after high school. Back then I was told that I was crazy as a bed bug in the psych word for wanting to do a hood blister like Aerohead has on the t-100. The biggest hold back is my truck has an almost perfect body(less the shi♧¥stock paint falling off paint, bad primer requires stripping to bair metal to fix) and that makes it difficult to cut into this 25year old ultra clean rig. Stock CDa is estimated at .45-.55 Aero Tonto cover =estimate/ prediction .203-.253 =57% reduction My goal of 40mpg is 31%above my current max of 29.3 this will take some time and looking outside the box. As with my Tonto. (Witch has miles of improvements available some compromise. Form over function. --- I'll try pulling the Headache rack , sliding the AeroTonto up to the cab . For the trip home. This will have several effects. 1 close the cab cover gap . 2 remove of the horns .(ladder rack). 3 smooth the transition from cab to cap. 4 delete the opening ability (making it like the other fixed position caps.) Wind providing the taire down should take 10min (I'll time ) and reattachment of the floating cap (with some ingenuity) up to 1/2 hr. --- ive had the rear closing attachment come undone at 60mph ... yikes... this was before the lift struts . It lifted aproxamitly 9-15" above the tailgate... Indicating the angle may be too steep (DARCO will anwser) there is definitely lift .(as apposed to down force). --- I need to redesign the hinges, to include a retainer/safty cetch . On bad roads, aka dirt roads with washboard. The front slid over off the hinges...yikes ... the wight part was only attached at the rear by 1 ratchet strap . The front dropped down about 6"and rested.this has happened 3 times in 30,000mi once at70mph and 2 on dirt roads at 35-40mph (As aposed to catastrophic lifting and by by) the redesign will include an alignment guild for the hinges to make installation less problematic in windy conditions. Well 4:00am a nother try at sleep. Dreem big chisel down to reality. |
chainsaw
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He was okay,but boy was that close. Glad all your internal parts are still inside! |
Darko
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I just got to thinking that I was cutting things to close.I didn't get to sleep until after 5:00 AM this morning (a new record). I hope this doesn't wreck you and your friends schedules. I'll be fabricating up to the departure date 'n hopefully have something significant to share. Hope you can still make it. |
Can do thank you for the week lead much appreciated.. starting to thrum with excitement. .. looking for to talking about a v2 AeroTonto.
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lead time
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Nothings working out here at all. The T-100 is gonna require repairs I can't absorb right now.Shuttling to town for parts in the Honda has wrecked my back. Parts are never in stock.Dealers never notify me when they come in.It's just eating away the calendar. I told Layne to take me off his list until I can get on my feet. If you can some how get away in the near future I'd still like to get your truck in to test.I don't like jacki'n folks schedules around like this. I'll keep fabricating.I just need to spread out some surprise expenses out over some time. Snow will be an issue before long,so. If you'll send me a private mail here at the forum we can exchange phone numbers to better stay in touch.I don't have a computer and getting to town to use one has become a painful operation. Again,sorry for all the trouble,Phil |
AWAOL in Ogden
Just arrived this morning. About 8am as I've made arrangements to take cair of other things wille in town took in some scrap witch will cover the trip( at$ 42.07southbound 27.07mpg personal best for this leg) Wilco on PM.
---- Steped up to Mobil Delvac 1300 Super Diesel oil https://mobiloil.com/~/media/testing...diesel-oil.pngat 280,543mi could not pass up the opportunity. Napa has it on sale right now for $11.99($23 off sale) a gallon that's cheaper than the conventional Dello I get from Costco at $38 for 3 gallons... had some wind but not to much . No CEON sum 3-7 second intervals(100-300m ) on trucks mostly south of ID about 100mi from Ogden ,before I came on one that had a similar PTW (power to weight ratio) was pulling 625EGT @70-77MPH insted of 7-750 EGT dont know if if was my interval or synthetic oil. Just imagineif I was willing to close the gap to sub 3sec and do what is referred to as illegal drafting. 30-35 mpg @70+mph is my guess but I'll never be willing to find out. .. ---- Experiment conducted Removal of headacher rack, running as a fixed cap. Slid 1/8"from touching the cargo light. No gap fill front or back. Results 2 tanks dated 9/6/2016 Northbound Anaconda Mt to Helena I-90 ,I-15 ,US12 25.89 mpg (US). 31.1 mpg (Imp). 9.09 L/100 km. 3.86 gal (US)/100 mi. 1301.61 Wh/mi Southbound Helena, Mt to Anaconda, Mt 27.6 mpg (US). 33.13 mpg (Imp). 8.52 L/100 km. 3.62 gal (US)/100 mi. 1221.18 Wh/mi Conclusion removal of the horns showed a minimum improvement with out closing the gaps . Had rain day before so cardbord cutout gap fillers had to be removed. (Also the first snow that lasted over 24hrs. ) winter is coming Pic to fallow later . Gumby Stay Flexible. |
Update. Pulling 21.21 - 24.75mpg @70mph/600Egt 4000mi
--- Spoke with a manufacturer of the Boat wrap. The reason for only giving a 12 month UV stable ratingis that the welds loose thire protection and start to delaminate. So far 11.9months intothe durability testing, several patches (thermo welded over burn holes)have delamed. And yet several have held with no sign of separation. The difference appears to be wether or not the plastic got hot enough. Just like torch welding steel there's a fine line between right and melting through. This is only on the skin side . On the in side of the AeroTonto were all of the seams are, things are protected from UV by the mylar on the fome and show no signs of delam. No cracking as with the painted V1.0 did in the thin spots x1 --- https://youtu.be/neBoqAxe9u4 Video after driving 65 - 70mph for 20mi on I-15. |
Pallet test
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A well thought out desins put to the test .1ton 50x40lbs bags of pellets + pallet centered over the axle .
If it fits it ships... Attachment 21285 Attachment 21286 Store was able to load it wirh forklift with the lift struts attached. Had the load been to tall I would be able to pop the quick release struts off then open past 90° vertical for crane loading . If I was going more than across town I would tarp to clean up the aero. |
fits
Nice utility!:thumbup:
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I have noticed a significant reduction in the volume of snow accumulation on the tailgate. Just about every PU hear in Montana has the complete back (top of tailgate/campershell to bottom of bumper) covered with thick snow kicked up in the wake.
Every PU I passed was Wight out even the lights this makes them hard to see, there head lights are a better indication of there presents than the covered tail lights. On December 24 I drove 100mi in hevy snow @60mph (droped to 45-50 on grades) this is all the snow I accumulated, driving out of the ruts to kick up as much snow as possable. http://ecomodder.com/forum/attachmen...6&d=1483506077 Notice the gap between the bed and bumper. This indicates to me air flow through the gap. And also the ball holes in the step. Have been kept open from air flow. |
That snow doesn't lie. Your truck has a better wake for sure.
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I didn't realize you were in Butte America. Did you just move there or have you been there all along?
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Next time this far south on I-15 we should meet up. Edit. Got threads mixed I mean east on I-90 or my next trip out west |
finally got to see what kind of an effect the horns have.
just got this up from January . some tuft testing on the horns of the Aero Tonto cap.
The camera seems to disturb more air than the 1/8" x 3" flat strap and horns 35 mph tuft testing horns from the top 1of many skyking how dose it look? sorry not going to be an ABA flow test on the horns. maybe on 2.0 I'll compromise the ability to carry long loads and leave the horns out. dream big chisel down to reality PS How dose a person post a you tube video so that it shows the playable image , not just the link? |
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