Project Extended Pop-Top Aerodynamic Camper Shell ('99 Tacoma)

[86toypickup]

Hey I've enjoyed this thread and all the pics Ive got an old 86 Toyota and have recently achived 39 mpg (with some hypermileing). I've ha plans in my head for a while now for an areo cap on a limited budget. After seeing the gas prices jump 40 cents I'm very motivated now to move forrwad with my plans. Can't wait to see what your mpg improvment is.

[Varn]

Old school rule's 39 mpg. Did you get 39 over 20 miles or 1000?

BTW gas prices are down here. Only double of what they were 3 years ago.

Originally Posted by 86toypickup

Hey I've enjoyed this thread and all the pics Ive got an old 86 Toyota and have recently achieved 39 mpg (with some hypermiling). I've ha plans in my head for a while now for an aero cap on a limited budget. After seeing the gas prices jump 40 cents I'm very motivated now to move forward with my plans. Can't wait to see what your mpg improvement is.

[86toypickup]

That was with bout half a tank comuting to work two weeks ago was about 38 and last week was 35. 35 is more of my average, after adjusting the nut behind the wheel its not too hard to get 35mpg. Not mods but this stock truck came with no power steering and no ac.

[86toypickup]

Hey varn that 39mpg was over 200 miles driveing about 60 miles a day

[skyking]

NICE!
I just got back to the forum ( working 6 tens and driving 120~180 miles on top of that per day!) and find this cherry project, read through the whole thing.
If there is a way to get inside the shell while it is down, and simply stand up with it, you don't need any lift mechanism IMO. Make the 4 side latches automatic, like a catch that you set to toggle over when the bar goes past.
Set the latches to lock ( by gravity ), lift up, and click, click, click, click, set down on latches.
Reverse process is set the latches to open, (bungees?) lift up, squat down. Just another thought. I can draw something up for you when this job settles down.

[ChazInMT]

SkyKing, Saw this in Bozeman a month ago.

[skyking]

That's cool! I've been into that airport before. Hot and high, use the turbos on takeoff

[gone7]

@86toypickup #91,
Me too. This is one cool test of what a person can do with modding a pickup.

I've been toying with the idea of a scrap late model compact pickup crew cab to convert to electric. I am wanting to see the results of this test. It should be significant.

[a8ksh4]

@86toypickup - way cool! Is yours a 2wd, std cab, manual trans?

[a8ksh4]

Originally Posted by Varn

I skipped how I do the layup, it goes something like this: For a wet layup we usually spray glue the composite onto the foam and then paint on the epoxy and use the peel ply.

So I could probably tack my cloth to the shell, paint in the resin, lay the rip-stop nylon/peel ply over top, and squeegee out the excess resin? Then pull the nylon off once it starts to set up?

Originally Posted by turbothrush

What weight is your cloth?

The sample I picked up was 8.8oz twill. Once the glass is on, I'm planning on doing a thin layer of polyester filler, primer, block sand, primer, and roll on enamel white paint (something else that I've been wanting to test for next time I need to paint a car). Might be nice to run through this whole process on a sample piece of foam to see how it works.


For most of the shell, a single layer of glass should be good. I'd really just like to double up and add strength around the edges and joints between surfaces, so I'll overlap the outside layer of glass with the inside layer where the shell meets with the cab as well as adding an additional 3" wide strip in the corner where the panel behind the cab meets w/ the outside of the shell and similarly at the back.


Like you guys are suggesting, it might be really simple just to have four hinged legs that drop into place as I lift each side of the shell up successively. The shell will clear the cab raising it like that. I would just have to come up with a door design on the back that works with that kind of lift... hmm...