The Amocat- 2005 Tacoma

[aardvarcus]

In other news, I roughed out my version 2.0 aeroshell with a handsaw. I will switch over to rasping/sanding from here to get to the final shape. I also need to pick up some lexan for windows.

[aardvarcus]

I have continued to make progress on the Version 2.0 Aeroshell. The cold has halted my welding or most progress on items that have to be done outside. I moved the shell to my basement to continue progress. I got my front viewing cutout made (no window there) to match the truck rear window. I also cut out for the window on the back of the shell (3’ wide, 4’ long), and I re-cut out the passenger side window to a slightly larger size. I also did some better smoothing of the passenger side. I still need to cut out and shape the driver’s side in the same manner. Then some cutouts and smoothing of the underside, and it will be ready for epoxy fiberglass. Anyway here are some pictures.

[BamZipPow]

Looking good!

One issue you might run into with the aero cap so close or touching the cab is that as the truck bed flexes towards the cab, the front edge will contact the cab and may start cracking the aero cap.

[aardvarcus]

BamZipPow,

Yeah, I learned from my half shell that you can't get them too close. I will try spacing it back about an inch or so when I go to permanently install it. My plan is to use a flexible gap filler, not at the outside edge but between the shell and the rear window. It is just much easier to attach something at that location.I don't know how much the outer gap will hurt the flow, but I would think blocking it from the inside would help to trap a pocket of air, versus having air flowing through. I am open for suggestions though.

[aerohead]

Originally Posted by aardvarcus

BamZipPow,

Yeah, I learned from my half shell that you can't get them too close. I will try spacing it back about an inch or so when I go to permanently install it. My plan is to use a flexible gap filler, not at the outside edge but between the shell and the rear window. It is just much easier to attach something at that location.I don't know how much the outer gap will hurt the flow, but I would think blocking it from the inside would help to trap a pocket of air, versus having air flowing through. I am open for suggestions though.

I'll be sealing the gap on the T-100 in September at DARKO 'n see what that looks like.The smoke appears to just jump the gap,but the load cells will tell us about drag.

[freebeard]

Has anyone considered or tried a strip of metal embedded in the leading edge of the cap, and a ribbon of magnetic car-door sign material glued or riveted to the back edge of the cab?

https://www.google.com/search?q=magnetic+sign+material

[aerohead]

Originally Posted by freebeard

Has anyone considered or tried a strip of metal embedded in the leading edge of the cap, and a ribbon of magnetic car-door sign material glued or riveted to the back edge of the cab?

https://www.google.com/search?q=magnetic+sign+material

I kinda tried it,just with taped on structures.Where I got in trouble,was at the upper corners where the greenhouse sides wrap over into the roof.The cab-mounted structure needs to be outside the bedcover structure in order to shingle the air.
During an abrupt torsional jolt,the inner 'corner' tears out the upper 'corner'.
The wind tunnel will help us know if it's even worth messin' with.If so,then I'd be inclined to attach an elastic,semi-rigid structure only to the cab and let it do all the deformation by itself.Big Rattlesnakes would work nice if I could figure out how to train them.

[freebeard]

I should have known you'd been there and done that.

So—two little slits to separate the flaps, or you could go full fishtail.

[BamZipPow]

This was my first attempt at covering up my cab to shell gap.
http://ecomodder.com/forum/showthrea...gap-14058.html

Even though it did okay, a better method of using VHB tape might be better in the long run.

[aardvarcus]

I finally finished the shaping of my foam aeroshell and used my rasp and sandpaper to finish marring up the surface so the epoxy fiberglass will be able to bond to it. Carried the shell back outside and got a few mock up shots of it on the truck. The shell then went into my garage so that I can begin putting the epoxy fiberglass on it. (Too much odor for inside.) Overall I am satisfied with how it is turning out.

My fuel log has been lower than normal recently because I removed my half shell and have not had time/motivation to reinstall it knowing I have to take it back off to test my V2 full shell. There is a noticeable difference in lift on the rear axle at speed without it on there. I consider this extra motivation to get the full shell done, unfortunately with competing priorities my time to work on this is limited.

Anyway, pictures. I did the requisite AST-II overlay, which while was not done from far enough away to a good side profile at least shows I have not drifted too far off from correct.