Echo-Troll Modding Thread (2005 Toyota Echo)
 

Hi Hypermilers!

HyperMileQC and I are starting an aeromodding project on a Toyota Echo 2005 Manual 5 Speed 1.5 L : The Echo-Troll Project!

Link to EcoModder Garage : Echo-Troll

EPA : 30 City \ 38 Highway \ 33 Combined MPG (US) | Fuel Economy

My MPG's : 60 to 94.4 MPG in a 4.2 Miles commute \ 60 to 93 MPG on HWY \ 65 to 90 MPG in a 13.7 Miles commute with 26 lights & 13 stops

http://ecomodder.com/forum/fe-graphs/graph5396.gif


Up to Date List of my Current Aeromods :

-Whiper Deflector (Tested) +1.5% MPG (US)
-Wheel Covers (Pizza Pan) (Tested) +2.15% MPG (US)
-Partial Front Grill Block (Winter Mod) + Upper Grill Block (Upgraded)
-Sealed Gaps Around Lights & Hood- Upgraded+
-Frontal Belly Pan Version 2 (Old version : Frontal Belly Pan - Upgraded+)
-Center Belly Pan Version 2 (Old version : Center Belly Pan)
-Rear Belly Pan - Upgraded+
-Front Wheel Spoiler Version 2 (Old version :Front Wheel Spoilers)
-Rear Wheel Spoiler Version 2 (Old Version : Rear Wheel Spoilers)
-Side Skirts Version 2 (Old version : Side Skirts)
-Passenger Side Mirror Deletion
-Rear Wheel Skirts(Removed for winter)
-Kammback Spoiler - Revised Angle


Planned Aeromods :

-Adjustable Grille Block
-Articulated Front Wheel Skirts
-Boat Tail
-Boat-Tailing Behind Tires
-Kammback Extension
-Nose Cone Front Bumper


Inside of the Car Modifications :

-Alternator De-Belted on Short & Medium Trips
-A/C Delete
-Engine Kill Switch
-Electric Water Pump & Fan Digital Controller - Installation & Testing
-4 Diodes On The EWP With A Switch
-ScanGauge II
-Engine Insulation
-Block Heater
-Oil Pan Heater
-Transmission Heater
-Synthetic Motor Oil : Mobil 1 Advanced Fuel Economy SAE 0w-30
-Synthetic Transmission Oil : Royal Purple SAE 75w-90
-Fresh Air Intake (Stock Intake Snorkel)
-LRR Summer Tires : Michelin Defender 50 Psi Front & Rear (Current Tires)
-Winter Tires : Tiger Paw, 40 Psi
-Ducting from Grille Block Hole to Radiator
-Power Steering Disable
-DRL Disable
-LED Lights
-Fire Blanket (For Winter)
-Power Steering Pump Remove
- LED Headlights

Planned Inside Modifications :

-Weight Remove


The Ultimate Goal :

my goal is to reach 2.5 L/100Km (94.9MPG) For now I haved reached 2.66 L/100Km (88.37 MPG).


The Car :

http://ecomodder.com/forum/member-ec...4-pict1153.jpg
You can see here the Echo-Troll with one of it's first Aeromod, the partial grill block for summer.

If you have any ideas or suggestions for this project, please, let us know by posting in this thread. Thanks.

Wheel Covers (Pizza Pans) DIY Fabrication :

Decided to put smooth wheel covers (pizza pan).
It was pretty simple, I bought some pizza pans and I nailed the cover on the original wheel cap. Took me 3 hours to make.

Here are some picture of the wheel covers :

http://ecomodder.com/forum/member-ec...5-pict1154.jpg
http://ecomodder.com/forum/member-ec...6-pict1155.jpg

The Wheel Cover :

http://ecomodder.com/forum/member-ec...8-pict1160.jpg
http://ecomodder.com/forum/member-ec...2-pict1161.jpg
http://ecomodder.com/forum/member-ec...3-pict1162.jpg

Results Of the Wheel Covers (Pizza Pans) Tests! :

Today we have tested the wheel covers to prove their efficacity and their FE with an A-B-A test.

Here are the Results :
11°C (51,8°F) / Speed : 50 MPH (80 Km/H) / 06 October 2011 / Good Conditions in general.

A = With the Wheel Smooth Covers (Pizza Pans)
B = Without the Wheel Smooth Covers (Pizza Pans)

In MPG (US) :
|-------|--A---|--B---|--A---|
Run # 1 |-61.2-|-59.5-|-62.4-|
|-------|---------------------|
Run # 2 |-57.2-|-57.1-|-57.6-|
|-------|---------------------|

Results :

Run # 1 Combined A = 61.8 MPG (US) (3.81 L/100Km)
Run # 1 Result of B = 59.5 MPG (US) (3.95 L/100Km)
Run # 2 Combined A = 57.4 MPG (US) (4.1 L/100Km)
Run # 2 Result of B = 57.1 MPG (US) (4.12 L/100Km)

Difference of 2.3 MPG (US) With the Run # 1.
Difference of 0.3 MPG (US) With the Run # 2

Final Result of the Testing of the Wheel Covers (Pizza Pans) :

We calculated a 2.15% gain in MPG (US) with the Wheel Covers. Yay!^^

Whiper Deflector in Coroplast DIY Fabrication :

Realized the wipers was really in the airflow so I decided to make a coroplast and duct tape whiper deflector to respect airflow near the wipers zone. It took me maybe 2 or 3 hours to build it. I made tests with the deflector but they are lost in the Void. We know that it is a 1.5% gain in MPG (US). Based on a A-B-A-B test. Inconveniant : some leaves and maple scrap get stuck in there.

Some Picture of the Wiper Deflector :

http://ecomodder.com/forum/member-ec...1-pict1158.jpg
http://ecomodder.com/forum/member-ec...0-pict1157.jpg

Partial Front Grill Block DIY Fabrication :

We are in Canada so winter is one of our preocupation. I decided to make a Grill Block to help Engine keep its heat. Its made out of Styrofoam and Duct Tape. Took me 1 hour to do and work well. Not tested. It is also blocking the hole for the fog lights (I don't have any).

Added upper grill block made of coroplast and duct tape.

Here are some Picture of the Grill Block :
Upper Grill Block :
http://img14.imageshack.us/img14/5301/img0414vu.jpg
The Front Grill Block in Summer Mod :
http://ecomodder.com/forum/member-ec...9-pict116a.jpg

The Front Grill Block in Fall/Spring Mod :
http://ecomodder.com/forum/member-ec...7-pict1156.jpg

UPDATE : This is a new picture of the Grill Block as it is actually in August 2012 :
http://ecomodder.com/forum/member-ec...8-img-0715.jpg

Went in Ontario this morning with echo-francis to take some electoral coroplast... We got 19 small and 11 large.
What does that mean?
Wheel skirts! Maybe belly pan. We will have a heated place to work on the echo-troll this winter, so we will keep you in touch with those improvements.
HyperMileQC

http://img42.imageshack.us/img42/5484/img0417xy.jpg
http://img204.imageshack.us/img204/271/img0418g.jpg

Cool ! Good to know that another Echo is going ahead with some aeromods.

This what I have done on my Echo so far :

http://ecomodder.com/forum/showthrea...cho-15673.html

Block Heater and Weatherstripping Tape
 

Block Heater and Weatherstripping Tape :
Installed a block heater on the car. I also found weatherstripping tape in my house and I sealed some gaps in the front.

Block Heater :
http://img443.imageshack.us/img443/2320/img0422mj.jpg
Weatherstripping tape :
http://img27.imageshack.us/img27/442/img0415nv.jpg

Rear Wheel Skirts
 

Rear Wheel Skirts DIY Fabrication :
We have fabricated some rear wheels Skirts, they are finished, and we had them installed for about 1 month. We removed them to swap the tires for winter, but we do not plan to replace them until the summer tires swap. here are some pictures :

Rear Wheel Skirts :
http://img526.imageshack.us/img526/1542/img0420k.jpg
http://img220.imageshack.us/img220/8560/img0419zn.jpg
(The neighborhood cat approves (AndrewJ) :)

ScanGauge II
 

The ScanGauge II :
We bought a SG II a year ago. We installed it here :

http://img841.imageshack.us/img841/590/img0421br.jpg

Working on the Echo-Troll today and it is going well! We will mod all winter cause we have a heated place to work.

Did you get the block heater from Toyota ?

I bought the Block Heater at Pièce d'auto Jarry in Laval.

http://img408.imageshack.us/img408/800/sansrekh.png

The Block Heater not installed :
http://img534.imageshack.us/img534/2...0021300900.jpg

How much did it cost, if you don't mind me asking ? Does it come with the install instructions too ?

Merci !

it cost about 50$ and yes it come with the instruction but the instruction was really complicated even my mecanic guy have to call toyota to find the way to install it. the image is a exemple, the block heater is the same but not the rest.

On peut toujours parler en français, mais je crois que ça serait mieux qu'on continue en anglais afin de faciliter la discussion avec les autres membres. :thumbup:

Bought myself a set of pizza trays and I was wondering how you attached them onto the hubcap. Thanks !

Good to know that you have decided to put some wheel covers on your echo!
It was pretty simple. We drilled 3 holes in the original hub cap, and in the pizza pan. Then we nailed it together with nut and screw. Did the same for the 4 wheels.

I don't know if you can see in the photo, but the nails are placed at the extremity of the cover. FYI : If you plan to put some Wheel skirts, make sure that the pizza pan do not take to much place, every inch is very important for good AF.

I just don't understand how the nail holds the pizza pan onto the hubcap. From what I can see in the pictures, it looks like a rivet.

Reason I ask is because I was thinking on using "pop rivets".

i use screw and nut to keep them attached

Ah, that was going to be my second guess. Thanks for the clarification ! :thumbup:

Wheel Skirts are done for about 3 weeks now. Echo-Francis and I were planning to see what we could do with the car. Thinking about Belly pan. We will have some photo of the rear wheel skirts this week-end maybe.

Frontal Belly Pan DIY Fabrication
 

Frontal Belly Pan DIY Fabrication :

Today, we have worked on the underside of the car for about 3-4 hours. Result : a new coroplast Frontal Belly Pan! Yes, we do not plan to test them tho, cause their hard to install, and pricey in duct tape. We plan to make a complete belly pan, we will make a center pan and a rear pan. for the future Boattail!

Here some pictures of the jacked car :
We jacked the car with bricks and 2x6. For the 2 Frontal wheels.
http://img196.imageshack.us/img196/9113/img0430rv.jpg
We have also placed 2 jack to securize the position of the car. And bricks behind the wheel to stabilize.
http://img402.imageshack.us/img402/4486/img0431ke.jpg

The fabrication of the Belly Pan :

First of all, we began to build the driverside Belly. it is all made of coroplast. We fixed it with screws in the plastic underbumper. Also put our best friend, duct tape to smoothen the belly. Here some picture of the first part of the belly pan :
http://img705.imageshack.us/img705/2261/img0433kh.jpg
http://img444.imageshack.us/img444/8559/img0432lg.jpg

After, we started the construction of the second part, the passengerside belly pan. Did the same as well, screw it in the bumper, and smoothen with duct tape. Here some pictures :
http://img26.imageshack.us/img26/4254/img0434sr.jpg
http://img856.imageshack.us/img856/4816/img0435xp.jpg
(Notice the cat :)

I thought the Echo already had a front belly pan, well mine does.

Be careful when using cinder-blocks to work under the car; they are prone to crumbling !

roll the cinder block 90 degrees so the openings are at the top/bottom. it is much stronger that way. the way you have it, it is likely to crumble.

nice job, so far.

This is a great thread.

One of the additional effects of your wiper deflector is it covers the fresh air intake at the cowl.

Restricting flow into the intake there may be similar to the concept of a grille block: better to send air around the car than through it, unless you need the air. :)

i dont need this air:) the fan works like before:D

Keep in mind that during Winter, it is better to have fresh air into the cabin for proper windshield defogging.

I would leave a small part of the fresh air intake open.

I love the look of your lower airdam block! The fact that you adjust it for the seasons is awesome haha!

I think if you could invent something to go over top of the upper grill on the outside it may be more aerodynamic in comparison to blocking the grill from behind.

Great little car!:thumbup:

Thank you Daverods! In summer, if the hole is to much grilled, radiator fan starts all 10 min, so we decided to put less grille, but when winter arrived, the engine temp was lower, so we decided to put more grille, and ICE temp is still alright running ~88°C. (Fan start at ~95°C).

The upper grille block is pretty simple, we cutted a coroplast in a surf board form, then, we zip tied it to the original grille. but the coroplast sheet is zip tied from the exterior, not from interior, of the bumper. FYI:)

Thank you MetroMPG, some of our inspiration comes out of your great mods, some of basjoos ideas and many others. the echo is being modded pretty well now that we are hypermilers, echo-francis and I.

And for the whiper deflector, the air blocked by the mod is not really cooling the engine, only taking the air under the car, and that's not good. We prefer to have it blocked, so the wipers and the grille are out of the flow.

Another thing, neither Me or francis have 250+ post on EM, so we cannot add this thread to the project library, if you could add it, it would be nice.

Denis

Rear Belly Pan DIY Fabrication :

That's it! after 7 hours of cruel back laying, the rear belly pan is complete! The result is excellent. We will do the center pan soon. Same thing as the frontal belly, made of coroplast and duct tape. used the cinder blocks to jack the car. (put them the other side, for more safety than the last time.)

Here are some pictures of the rear underside of the car :
http://img31.imageshack.us/img31/4859/img0446ni.jpg

The pan :
http://img443.imageshack.us/img443/5963/img0447cd.jpg

The rear belly pan :
http://img807.imageshack.us/img807/4291/img0449jm.jpg

For the muffler, we put some screen so it can cool and to deflect some of the air.
http://img847.imageshack.us/img847/9907/img0450ma.jpg

Other thing :
HypermileQC and I are going to the Salon de l'Auto 2012 at place bonnaventure in mtl. If someone is going too, plz tell us! We are going saturday 14 or sunday.

Front Wheels Deflectors :
 

Front Wheels Deflectors :
Made some deflectors in coroplast and duct tape. Took 10 min to make and to install.

Some pictures :
http://img545.imageshack.us/img545/1773/img0451n.jpg
http://img841.imageshack.us/img841/5026/img0452dv.jpg
http://img402.imageshack.us/img402/2029/img0453hj.jpg

Cool ! I might join you guys then. I will let you know for sure next week.

Keep up the good work ! :thumbup:

Finally we are going at Salon de l'auto Saturday 14. FYI :)

Also : Plan to make the center belly pan soon!

Désolé pour le retard, mais je ne pourrai pas me pointer au salon de l'auto ce samedi.

Amusez-vous !

PS: prenez pleins de photos.

(Français) :
C'est pas grave, on a eu ben du fun! Il y avait une simulation dans un kiosque de CAA Québec, c'était pour l'écoconduite, la moyenne des gens était de 8,8 LHK, et le Highscore était de 6,9 LHK, lorsque nous sommes partis, la moyenne était de 8,5 LHK et le Highscore était de 4,9 LHK! Nous avons obtenus le même score tous les deux. Bref, c'était bien! Désolé cependant, nous n'avions pas de caméras au salon malheureusement...

(English) :
It's okay, we had fun! There was a simulation in a CAA Quebec stall and it was for eco-driving, the average was 8.8 LHK, and LHK Highscore was 6.9, when we left, the average was 8.5 LHK and the highscore was 4.9 LHK! We obtained the same score both. In short, it was good!

Other thing, on the HWY the last day, the hole in the grill block got stuck because of snow, (We had previously taped a screen to protect the radiator from rocks). The fan was kickin all 4 Mins, we were obligated to stop and remove the screen... This proove us something tho, the screen used near the muffler is really deflecting air! :cool:

We will work to upgrade the rear belly pan, new pictures soon! :)

Rear Belly Pan Upgrades
 

Rear Belly Pan Upgrades :

We have worked today to improve the efficiency of the rear belly pan. We have retouched the belly in the muffler zone, by screwing the screen instead of just taping it. We have reshaped the little part of the belly so it fit nicer and to remove gaps.

Some Pictures :
Here is the difference between the older part and the newer. Look at all the dirt! :
http://img6.imageshack.us/img6/4539/img0454yg.jpg
Here is the rear belly with the new part replaced and with better quality duct tape :
http://img692.imageshack.us/img692/1694/img0455tb.jpg
Compared to an older picture :
http://img807.imageshack.us/img807/4291/img0449jm.jpg

Rear Wheel Arch Mud Flaps
 

Rear Wheel Arch Mud Flaps :

When we realized that the rear belly pan was acting like a parachute, and that dirt was accumulating, we decided to make arch mud flaps, with coroplast dans duct tape, as always!:cool:

Took us about 1 Hours by side and with no such effort. We screwed the flaps to the rear belly pan for more strenght and durability.

Here are some pictures :

Passenger side Rear Wheel Arch Mud Flaps :
http://img6.imageshack.us/img6/9830/img0456on.jpg

Driver side Rear Wheel Arch Mud Flaps :
http://img835.imageshack.us/img835/9712/img0458wy.jpg
We had to work differently for the driver side because of the gas tank pipe and the light cables in the way.

We have started today the center belly pan. But we have noticed alot of oil in the engine bay. So we removed the frontal belly pan to examine. We don't know if it is from the oil pan, the filter or from another leak. I'm hoping it is not this. It is the first time that the car have Syntec oil, and syntec oil is thinner, so we don't know if the problem was anterior or after the oil change.

http://img822.imageshack.us/img822/8022/cbpf.jpg

Frontal Belly Pan Upgrades
 

Frontal Belly Pan Upgrades :

Now that the oil leak is gone, we have replaced the Frontal belly pan. Did some upgrades to it. Instead of being duck taped to the bumber, it is now only screwed. We realized that removing it was using alot of tape. So to keep it gapless, we put some weatherstripping tape.

Here some pictures :
Look at the WST
http://img809.imageshack.us/img809/22/img0470d.jpg
http://img525.imageshack.us/img525/4034/img0472qg.jpg
http://img839.imageshack.us/img839/3904/img0471cgv.jpg

And the final result, look at the center belly pan frame:)
http://img545.imageshack.us/img545/655/img0473z.jpg

Before upgrade :
http://img26.imageshack.us/img26/4254/img0434sr.jpg