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Old 07-26-2012, 04:54 PM   #11 (permalink)
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Looks good, what is that upper grill block made of?

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Old 07-26-2012, 05:39 PM   #12 (permalink)
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Corrugated plastic. I took my time, copying the curvature of the hood (which mimiced the bumper as well). Then, I made 4x "wedges" for the sides and 2 braces (which gave it the final angle, 2 braces were placed in ~1/3rds under it). Finally, a thin strip on the back for further bracing... then taped it all together and taped it on! Meant to snap a pic before it went on... whoops I can take further pics of the back side of, though, if you want more of an idea of it. I plan to extend it to cover the blinkers and either relocate them, or use some thin plexiglass to have them blink through it.

I threw together a little mspaint diagram of what the cuts looked like...


Driving around today, top I saw was 197*F on a mix of city and highway, but often going lower than that.
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Old 07-26-2012, 05:56 PM   #13 (permalink)
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Thanks, I've been meaning to get the top done, just havent done it yet. Need to get it done before my bday concert.
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Old 07-26-2012, 11:16 PM   #14 (permalink)
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Quote:
Originally Posted by TOOSTUBBORN2FAIL View Post
Thanks, I've been meaning to get the top done, just havent done it yet. Need to get it done before my bday concert.
One tip for ya: When you go to cut the plastic sheeting, to get the curve of the hood/bumper, just put it slightly under the hood until the two corners line up and are under... leaving the curve to overhang in the middle of the sheet. Then, take a sharpie to it... it was very easy and fast. Cutting straight, however, is a pain.

Also, when I did my 4 angled peices, I just moved them back and forth to get the proper height. The two sides first, then did the middles. Took a little bit to get it perfect, but once I did, was easily to line it all up.

Is there any recommended glue for putting cloroplast together? I think hot glue would melt in hotter temps...
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Old 07-28-2012, 12:55 PM   #15 (permalink)
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BZP T-100 (2010) - '98 Toyota T-100 ext cab - 3.4L/auto SR5
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Quote:
Originally Posted by NoD~ View Post
Is there any recommended glue for putting cloroplast together? I think hot glue would melt in hotter temps...
I think you meant Coroplast...

Hot glue is okay fer filling in holes in Coroplast but when used on Coroplast...it will detach over time when under stress.

I've used 3M Super 77 spray adhesive with good results. Not sure how long it will last though. The spray adhesive (when applied properly) will handle most tasks...but if you use it on Coroplast in a high stress arena...I'm not sure it will be able to handle it.
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Old 07-28-2012, 04:19 PM   #16 (permalink)
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I think the best method of fastening Coroplast together is a mechanical fastener if the panel is under stress. Zipties, bolts/washer/nuts, DZUS fasteners, screws, or some combination of those.

Look at how the USPS puts their Coroplast containers together that hold the mail at the post office.
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Old 10-16-2012, 09:54 AM   #17 (permalink)
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Any updates?
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Old 10-16-2012, 10:08 AM   #18 (permalink)
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Sadly, I have been too busy to work on this project. Most of my drives are 4-5 miles at a time, so fill-ups are once a month at best. Usually getting ~45MPG on average. I'm still waiting on my custom coil-over setup to be finished from the factory so I can lower this ride, getting further into the aerodynamic wonderland that it should become.

With winter around the corner, I definitely don't want to go too crazy as the results will be pretty hard to compare with the harsh cold effecting my MPGs.

I will probably start on the hatch-back conversion in the spring. My current factory back window's window tint is beyond legally blind levels! So I definitely need to get that done. Should help quite a bit with aerodynamics as well.

Outside of those basic aerodynamic mods, I'm really thinking this engine is going to be my weakest link to insane economy. It idles at .30-.34 GPH. I run with a lot of engine-off, but it's still not the efficiency it needs. My wife's Xb, with a 1.5L DOHC, idles at around .15! That's half the fuel to idle an engine that's 3/4 it's size. Though, I'm still not sure what route to go for an engine replacement. I keep eye-balling going all out and hitting electric (especially since my primary use of the car is work and back, 10 miles total per day tops!)... It's all up in the air at this point, but I want to get aerodynamically correct first!

So to complete this "update", I can say the car works well, heating has not been an issue w/ the current blocking (especially entering colder times), and this project is on the backburner, but not in the archives!

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