t_vago's compound curve foam board pickup aeroshell

[ecofreak]

Would Tyvek be a good candidate for covering the aerocap? Tyvek now comes in sprayable form if you'd want to preserve the shape of your cap as best as you can, but fabric sheets of Tyvek would be awesome as a non-rigid base layer and are pretty easy to obtain. I'm thinking of using some shreds of Tyvek (obtained from dumpsters) and the liquid stuff as a sort of heavy-duty papier-mache.

Here's a link, if you're interested.

[t vago]

Originally Posted by ecofreak

Would Tyvek be a good candidate for covering the aerocap?

I suppose it could work. I could not find very much on the DuPont website saying if the liquid form of Tyvek was compatible with styrofoam, but there were other building-related websites that basically stated that this liquid Tyvek was compatible. However, I'd do some testing first.

I now have a (mostly) light blue aerocap. The skin's much stiffer, too. As you can see, I've filled in that huge gap between the cap and the cab rear.





More FE results, too:

Before
To work: 59 miles / 3.05 gallons = 19.3 MPG
To home: 59.2 miles / 3.10 gallons = 19.1 MPG
Combined: 118.2 miles / 6.15 gallons = 19.2 MPG

Now:
To work: 59 miles / 2.76 gallons = 21.4 MPG
To home: 59.2 miles / 2.85 gallons = 20.8 MPG
Combined: 118.2 / 5.61 gallons = 21.1 MPG

It's about a 9% decrease in fuel consumption, or almost a 10% improvement in FE.

[skyking]

what did you put on it? Those are some very nice results, congratulations are in order.

[SoobieOut]

Very well done!! Congratulations on the numbers!

Would love to see an added section, perhaps a trailer hitch boat tail?

I remember as a kid watching a newsreel of a Goodyear, inflatable airplane. Came in a crate. Within 20 minutes it was inflated and flying. Would love to see an trail hitch inflatable boat tail.

[phunky.buddha]

Wow. Impressive numbers! Now I want to build one for my Frontier... has to be cheaper than importing a 2k Euro bed cap from Italy.

[ChazInMT]

Job well done, I read about the tyvek stuff, sounds like a good "primer" coat, then I wonder if you could paint it basic black?

[WD40]

This product is compatible with Styrofoam
Solarez Zerovoc Styrofoam safe UV cure resin, UV Resin, UV Resin manufacturer, UV Resin Supplier, Wholesaler, Wholesale,

[aerohead]

At 21.1 vs 19.2,if you drove the statistical 45% EPA HWY miles out of each years statistical 12,000 miles,over the 12-year life of the truck you'd save $ 1,063 in constant 2011 dollars ( @ $3.50/gallon ),and reduce carbon dioxide emissions by just short of 3-tons.
When the truck wore out the cap could go onto another pickup and do it for another 12-years on that truck, ad infinitum.
Nice parlor trick!

[dcb]

Vago, have you considered a lower ratio rearend gear? It might be cost effective to do so with some shopping around.

Here is the thinking in case it isn't obvious. It is not your exact engine but you get the idea hopefully, follow the arrows:

[ecofreak]

Originally Posted by ChazInMT

Job well done, I read about the tyvek stuff, sounds like a good "primer" coat, then I wonder if you could paint it basic black?

It's basically "white-out" for construction site paper. Tyvek is able to take on ink, paint, etc. so it would be possible to paint over it.

The best part is that you could mix sheets with liquid applicant for complicated bits, and have a good base for rigid epoxy/fiberglass.