F150 aerocap design and construction

[plasticuser]

I saw that you did that in your thread. I don't want to do that because in this area, the police are liable to write tickets for anything they're not accustomed to, and they often write tickets for people who leave their tailgates down when not carrying a load. They twist the "nothing sticking out more than 6" from the vehicle" law we have locally.

I did the tail as a rough experiment, knowing I could easily cut it off if it didn't work. I chose the shape because it is longest in the center where the airflow is most stable, and shorter at the sides. Also, it was easy to do with two screws, a sharpie and a loop of string.

I will attach a brake light under the lip of the tail, since I don't want a ticket for an obstructed tail light either.

I drove to the airport and back last night in cold conditions with medium winds from the south, and for my round trip, including in town and traffic, plus circling the pickup circle at the airport, I got 22.5 mpg on the Ultragauge, with my 90% skinned cap. So far, I am quite happy with it.

[plasticuser]

Originally Posted by GeekForLife

Make sure you use Bondo Gold, its what I use on cabinets when there going to be lacquer finish. I thinly coat the entire surface and then lightly sand. The finish paint is so smooth you cant tell its wood.

Normal Bondo is to much work

Good advice, which I will take. A little extra expense is worth it. I've used regular bondo in some car restorations and it is time-consuming to get the perfect results...

[GeekForLife]

I am curios how the project is going, any progress?

[plasticuser]

I have been tied up doing some contract work (I design parts to keep antique computers running) and the weather has been a bit.... damp... so very little progress has been made.

I will get back to it in another 3-4 weeks.

[plasticuser]

3-4 weeks ended up being 3-4 months, but I have pulled this out and dusted it off.

Updates will be posted in a couple more days.

[CargoBoatTails]

Originally Posted by bondo

It would be best to ask aerohead about the rounded back end. A boat tail extension may be best that mounts on the lowered tailgate. That will get you another 24" back and then you can also haul 4x8 sheets of plywood laid flat in a 6.5 foot truck bed and keep the wood dry too.

Bondo

This is exactly what I imagined.