Another truck aero cap idea...

[BamZipPow]

Got the bottom supports roughed in...


Now to setup the side support and then make the top support so I can attach the hatch to it. Hopefully I can lose the center support beam I have in there now.

Not going with the EMT pipe fer now...too much work before I have to hit the road on Tuesday. Headed towards New Braunfels...

Might be able to git the hatch up and running by tomorrow evening...we'll see.

[BamZipPow]

Here's how I wrapped the Coroplast around the bottom support beam. Shouldn't git any leaks...if it rains.







I'm thinking about going with FRP as my material of choice...if I can bend/wrap it around the beams. Should prove interesting...

The FRP will wrap around the bed rail beam so the edge will be on the inside and secured with screws. This should "protect" the wood from gitting water directly on it as no screws will be showing on the outside in the elements. Still haven't figured out how to do a rain channel fer the hatch though. I guess I'll git there eventually.

I guess if I really want to UV protect the FRP, I can have all the pieces Line-X'd...

Not sure what to do fer windows yet. Fer my Coroplast temp construction...I'll just use some clear plastic...

[graydonengineering]

Cool, it's staring to come together! Looks like I am not the only one sweating after work every night doing aero mods!

[BamZipPow]

A quick and dirty mock up so I can git my angles and brackets marked out...


During my trip to Home Depot to git supplies...I got a lot of people staring at my truck and cab cover. I put my aero package back on the truck sans the wheel skirts and extended diffuser. Guess they don't know a good thing (or two) when they see it...

[BamZipPow]

What a rough day...but it's almost ready fer skinning and the hatch!

Here's the front/top support that ties the sides together...


I can skin the top support frame so it's the optimal shape without worrying about whether the support matrix can match it.

The hatch will be about 6' long and will still extend up to where the tailgate is when the tailgate is down. The rear opening is 48" wide...

[BamZipPow]

Needed to add in a quick front support fer the side skin...

[BamZipPow]

Sides are on!


The sides are super stable now...may not need the top support after all! Thinking about making the hatch just as long as the sides...time to go git some more 2x3s and fit them up.




A quick look/fit with the old hatch...

[BamZipPow]

Hatch is framed...




Need to go git some brackets and couplers so I can hook up my gas struts. We'll see if the $5 struts will hold up this massive puppy up. Might have to break down and git some stronger ones. The brackets I'm gitting will be able to handle the heavier load...

[t vago]

Yah, those pieces of wood do appear to be pretty heavy. Then again, you should not have to worry about flying pieces of aerocap.

[BamZipPow]

Struts are installed...seems to lift just fine...but that's just the frame.



Closed...


Open...


Now I'm at that stage where I am trying to decide where to install my domed/sloped cover or a flat cover...