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-   -   Another truck aero cap idea... (

BamZipPow 11-12-2010 01:03 AM

Another truck aero cap idea...
Now that I have all this coroplast...I was thinking... Make an aero cap strictly just fer aerodynamics and not security. Make it with 3 layers of 4mm coroplast with the middle layer sandwiching some lexan fer viewing. Maybe even incorporating some real side glass from a used vehicle... ;)

It would still need some sort of framing to keep it on the truck bed lip.

I guess the key would be to git the correct angles to make it effective and simple to access the bed with. I know I don't want to use a bunch of adhesive to stick the sheets together...maybe some spaced out spots instead of slathering it on the coroplast.

I guess fer a second step (if this proves successful) is to cover it with aluminum flashing to make it somewhat secure from knives or what not... :D

Thoughts? ;)

d0sitmatr 11-12-2010 08:50 AM

I was thinking the same thing the past couple of days, but decided against it due to the very security reasons you brought up.

to attach it wouldnt need to be all that hard, you could use double stick tape with wide head pop rivets (or wide spacers + pop rivets) placed every 12", should hold it nice and tight to whatever frame work you go with.
if you have the coro to work with and a little time on your hands, I cant see why you shouldnt just go for it.

BamZipPow 11-13-2010 03:11 PM

I'm thinking about chopping the top off of my spare camper top so only the bottom frame, front (with sliding glass window), sides (minus the sliding glass windows), and a little bit of the top are left. I can then build up dual layers of coroplast on the sides and git the correct slope angle to the rear. This platform should allow me to adjust the slope angle just by chopping the sides down. I can always put in windows as I progress... :D

The rear hatch will not have a window in it while I test. I'll eventually have to git a rear camera system installed so I won't be totally blind back there.

BamZipPow 12-05-2010 06:08 PM

Got the camper top off and went fer a test drive empty. :D

I left my sliding window "umbrella" in place on the roof which sorta acts like a ducktail. Combined with my extended air dam, full belly pan, 11" side skirts, and rear diffuser, I found it interesting that my short run up North with the tailgate down gave me some pretty good mileage...22.95 mpg. With the tailgate back up, I got 25.53 mpg on the return trip. :D

Currently working on my grid panel with 2" spacings so I can git a better idea of where the slope should be. I'm surprised someone hasn't made something like this before. I plan to stick the panel in the stake holes in the bed and then take my photos. ;)

BamZipPow 12-05-2010 07:12 PM

Here's a quick mock up of my grid panel... ;)

A quick extension to the ducktail...

BamZipPow 12-05-2010 09:19 PM

Side view of the extended ducktail...

BamZipPow 12-06-2010 08:13 PM

The extension to the roof ducktail was bending the main piece I took the extension off fer now until I make a bigger ducktail to put on there. :(

Just got done making my stake hole will bolt in place to hold the main rails in place. Two bolts per side and it can be removed fairly quickly. :D

I'm making a quick half tonneau with a steel stud support frame to git some quick numbers. I can make it into a full tonneau with another sheet of coroplast. :D

BamZipPow 12-07-2010 08:11 PM

Got my main rails bolted in...

Was doing some thinking and some messing around. Came up with an idea of using 2 sheets of 4x8 coroplast fanned out so it will cover the span of the top of the cab to the width of the bed.

This is just a mockup... ;)

BamZipPow 12-07-2010 08:24 PM

Thinking about using some " Sch 40 PVC pipe and drilling holes in the main rail at the proper angle. I can then insert them into the holes and they should be able to stand on their own. :D

I plan on putting a landing on top of the pipes so the top can be supported as it lays down. ;)

Big Dave 12-07-2010 08:41 PM

Good start, BZP, but it looks like you are making the same mistake I did...too steep a downward angle.

Mine was 17 degrees. I should have had the height above the tailgate to be about 8 inches. Do the trig.

I do like the ducktail. How are you planning to attach it?

Your side curtains are killer.

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