Replacing Class c motorhome body for touring act

[pete c]

Here ya go....

Shuttlebus Handicapped

[slowmover]

So now I need to change my plans a bit.
It seems pretty evident that If I can have a box truck, then I should try and get a diesel, then modify it instead of my dodge to get the best mileage I can.

What do you guys think?

Many, many examples of this on Pirate4x4.Com - The largest off roading website in the world. in the Tow Rigs & Trailers subforum where members buy Ford diesel-engined U-Haul box trucks and modify them. My bar none favorite "restoration thread" (which includes aluminum travel trailers, etc) is by RoosterBooster on this thread. As a demonstration of skills, it is awesome. The tech discussion accompanying it is just as impressive. While it might not be to your or to their desires directly what you wish to accomplish (these are 4WD guys looking to take their Jeep & junk out to offroading sites), there is no end of the problems and solutions involved in modifying a cheap old box truck.

Your desire for a higher mpg business vehicle is a tangent. But all the mechanical, electrical, water & gas plumbing issues are covered in any of dozens of threads.

You'll be reading awhile, friend!

.

[capturedbyrobots]

Well, I'm back! How's it going?
I've been looking for diesel box trucks lately, and am just not finding what I'm looking for, so I've decided to modify my camper a bit for the next tour.
My goal is to get 3mpg better than my current 7mpg.
I average 10k miles on a tour, and if gas is at $4 a gallon (hopefully less) at 7mpg that's $5700, at 10mpg that's only $4000. That 10mpg figure would be well within my budget for this trip.
Tell me if you think these mods will give me 3mpg.

1. Less bricky- I'll chop off the sleeper
2. All wheel wells covered, Also side skirts added
3. Small mirrors
4. Build small truncated tail
5. Air vent covers
6. Front air dam and partial grill cover (lots of wasted flat spots)
7. Fan clutch

That's what I think I can reasonably do before tour....
Will it give me the few mpg I'm looking for?

[freebeard]

You're wishing for a 50% increase in efficiency.

1. Less bricky- I'll chop off the sleeper
2. All wheel wells covered, Also side skirts added
...
4. Build small truncated tail
...
6. Front air dam and partial grill cover (lots of wasted flat spots)
...

These could made some degree of improvement, depending on how they're done; The others are fine tuning. IMHO, even if done perfectly, they would only get you half way there.

[capturedbyrobots]

All I know is that the sleeper physically lifts up because of wind resistance sometimes.
That's the worst thing for sure. I've reinforced it though with steel now.
I feel as though that giant flat underside of the sleeper where the air rushes up the windshield and slams into it gives me even less efficiency than a a brick. It's a giant sail slowing me down, that's why I thought that getting rid of it would help me over 50%.

[ron22]

I do not think you will get up to 10mpg but good luck and let us know how you do.
I do think cutting off the sleep were it over hangs the cab will help.
I also think I would go with air dams as los as you can get them all around it. CLeaning up the bottom of an RV to install a belly pan would be a real chalenge.

[capturedbyrobots]

I have been mulling this over and decided I just had to know what would happen if I chopped the sleeper off mpg wise. So chop chop.!
It's almost done, looks like a poor mans fat sprinter now. It's not perfect, but I did my best. My neighbors thought I was nuts.
I still have a sleeping area, and the aerodynamics are much improved from the awfulness that was a standard class C.
I lost about 200lbs from removed windows and wood.
Also spent some time playing with the engine's tune. Found a pretty substantial vacuum leak, and fixed it. Up to 19inches vacuum at idle now.

Plans to do before tour:
Truncated removable coroplast tail
Partial grill blocking
Coroplast side and front dams
Small mirrors (the ones I have now are HUGE, like 1ft by 6inches)

My goal is still 10mpg, but even if I just get 1or 2 mpg better it would be worth it.
Pics in a bit.

[capturedbyrobots]

It's all framed in and sheeted and glued tight.
Just have to get some more aluminum to finish the sides and make a smooth transition from the windshield to the sleeper.
Got the wood work/bed/insulation done today.
The best thing is that if it needs to be changed, it's pretty darn easy to change at this point. I tried to get the best curves I could with the wood that was available. All reused wood from the original sleeper.

[ron22]

You should have done some MPG testing before and after the sleeper modifcations.
On the Mirrors they look like they are alot farther out then they need to be. Just makes sure you can see around the beast.

[capturedbyrobots]

Well, with the vacuum leak and old sleeper, it was 7mpg on a trip to LA and back.
Figured it out by gas purchases and mileage. Low mpg is pretty easy to figure out.

So how much was the vac leak robbing me, and how much did the sleeper mod help?
No way to know sadly. I still have the leaky diaphragm so I could plug it back in, but I'd rather not waste any more gas :$