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Old 12-13-2009, 04:48 PM   This thread is in the EcoModder Project Library | #1 (permalink)
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Aeromodding my 2003 "Classic" NHW11 Prius.

If you didn't get the memo, I recently revived a 2003 Toyota Prius NHW11 with 168000Km and a toast transaxle. Link in my signature.


Now it's time to start the Aeromods. The season is all wrong but when spring rolls around, I'll be ready to go! I'm happier working in the shop in the winter anyway.

My wish list of mods (I've been a good ecomodder, Santa) is as follows:
1) Grille block. Done
2) Basjoos headlights and hood. Done
3) Smooth wheel covers. Done
4) Front undertray. Done
5) Full undertray.
5) Plexiglas "double rear window".
6) Wheel boattails.
7) A-pillar tape VGs. Done
8) Rear wheel skirts.
9) Front chin air dam. Done
10) "Side Kilts" Done
11) Side trailing edge lips.

I think that about covers it.

Obviously this will be a while in the making but I'm pretty motivated.

I have already started on the first three so I will copy some posts to save time...

Uber-moonie sneak preview...





They are just Ikea candle platters. Heh. Ikea hack. They are 18" and heavier gauge than the $60 stainless pop on's that I have on the van. I will post mount them with 3 or 4 flat head socket screws tapped into the alloys through thick wall tube. They will need a bit of standoff so they don't rub on the rubber during cornering.

I like that they look like I'm running wide 45's on 18" rims but I'm really on 175-65-14s. they also have a smoother transition than moonies because they cover the part of the tire that curves back into the rim.

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Old 12-13-2009, 05:12 PM   #2 (permalink)
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First one done. I changed my mounting system slightly from my first idea to save weight and complexity. These are mounted with 1/4-20 NC cap head socket screws. I will relpace with stainless once I pick some up.

I carefully laid out the discs and drilled 4 3/16 pilot holes. I then used the disc as a template to mark the aluminum rim. I measured the offset and calculated the depth of hole required to drill and tap. Drilled the pilot holes with a special drill attachment to stay square. Used the same attachment to tap first with a spiral tap, then with a bottoming tap. Then I drilled the pilot holes on the discs to 1/4", popped in the screws and backed them up, slightly loose, with 2 nuts tightened to each other to keep the disc tight but allow the screws to be aligned and tightened into the rim.

Seems to work well. The gap will be adjusted on the next ones, a bit tighter to the wheel. I calculated about a 2.5mm gap will keep the sidewall free of the discs for most tire deflections. I can always cut the rims to a smaller diameter later if there are problems with this set up.





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Old 12-13-2009, 05:28 PM   #3 (permalink)
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Oh HELL YEAH !
That looks worlds better than stock !
Looking at your car from a stylistic viewpoint, the stock wheels look ridiculously small compared to the rest of the car.
The end result is that the car looks like it has 'chicken legs' and has a puny,weak stance. ( And that's why muscle cars look like they have a powerful 'pouncing' stance. )

You not only cured the problem, but made the car look like what I grew up wishing cars of the future would look like.

Well done.
I'd like to copy you on this idea.
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Old 12-13-2009, 05:34 PM   #4 (permalink)
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Quote:
Originally Posted by orange4boy View Post

Uber-moonie sneak preview...



.
Ooooh. She's such a tease !
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Old 12-13-2009, 06:05 PM   #5 (permalink)
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Forget the skirts, that looks too awesome to not do in the back too.
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Old 12-13-2009, 06:18 PM   #6 (permalink)
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I'd do the wheel covers and the skirts. Dunno why, I just would.

Those covers are eco-pimpin. How much are they for 4?
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Old 12-13-2009, 07:14 PM   #7 (permalink)
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$14.99 each. They are 18". There are also 12" versions for the little wheeled crowd at about $8 each.

You can't be squeamish about drilling your rims though. If mine were nicer, I probably would have gone for the real moonies which need only tiny holes right at the rim edge but mine were well scratched from the previous owner's interesting parking procedures.

You could probably mount these on steelies too, just with the screws closer to the centre.
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Old 12-13-2009, 07:20 PM   #8 (permalink)
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Little mo' 'spensive than I's thinkin', but I'll be checkin' 'round fer other options as well.
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Old 01-02-2010, 04:38 AM   #9 (permalink)
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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
Thanks: 84
Thanked 261 Times in 150 Posts
Had some time to work on the aero mods.

Second wheel disc installed. Now with stainless screws!

If you look closely you will see the a-pillar VGs that I made from magnetic strips. (I'm in my vortex generator stage) I'm mostly trying these for noise reduction. Cheap fun.



New front belly tray installed. The old one was a big aero mess. This will also help keep the heat in the engine compartment. I cut up the old tray and left the side panels in which cover the engine sides and such from wheel spray. I used the stock mounting clips on the leading edge.



Grille block's done but there's nothing to see as I blocked the inside.

I also basjoosed the hood and headlights with foam tape which also helps keep the heat in the engine compartment.
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Old 01-02-2010, 02:11 PM   #10 (permalink)
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How about a PN or link for those candle trays?

I think I might get a couple or 12.

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