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Old 06-23-2012, 10:56 AM   #1 (permalink)
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Testing aeroshell/boat tail For the Dodge

Later today, I am starting a testing aeroshell with integrated boat tail for my truck. No scangauge, I drive it few miles a year, so i am cutting right to the chase. I call it A-M-A testing
I am picking up the template at station 10, a point with 3.5 slope. I figure that will get me down faster, and is not a huge departure from <Shatner voice> the ...beauty , that is....the, template </Shatner voice>.
Length is still not a concrete number. It is somewhere around a total length of 12'.
I welded up my headache rack yesterday, and I will hinge this whole thing off it IF/when I build the permanent one. this one will probably be fixed for testing.
I have some nice big sheets of virgin cardboard to skin it with. A ton of scrap lumber, fasteners, some old gate hinges, etc.
I can borrow the tail lights and a pigtail for the lights.
Why now? I have a 320 mile 55~60 MPH round trip across the mountains to do Monday/Tuesday, and maybe a 450 mile 70 MPH freeway run in the middle of that, fuel paid. These opportunities just do not fall off the trees.

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2007 Dodge Ram 3500 SRW 4x4 with 6MT
2003 TDI Beetle
2002 TDI Beetle

currently parked - 1996 Dodge 2500 Cummins Turbodiesel
Custom cab, auto, 3.55 gears
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Old 06-23-2012, 11:51 AM   #2 (permalink)
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2004 CTD - '04 DODGE RAM 2500 SLT
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Fuel paid, no kidding!! Looking forward to it.
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2004.0 DODGE Ram QC/LB 2500 2WD/NV-5600 305/555 ISB. 7,940-lb. Stock. 200,000 miles/5000-hrs @ 40-mph average.
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Old 06-23-2012, 12:15 PM   #3 (permalink)
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Photos. We need photos.
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The vacuum gauge plus wheel covers helped increase summer 2015 mileage to 38.5 MPG, while summer 2016 mileage was 38.6 MPG without the wheel covers. Drove 33,021 miles 2016-2018 at 35.00 MPG.
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Old 06-23-2012, 12:23 PM   #4 (permalink)
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Woody - '96 Dodge Ram 2500 SLT
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90 day: 23.82 mpg (US)

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90 day: 15.1 mpg (US)

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Right now, it sits in my noggin. I have to build a linux server first, that is the reason for the trip.
I hope to have some framework constructed today that will be picture worthy.
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2007 Dodge Ram 3500 SRW 4x4 with 6MT
2003 TDI Beetle
2002 TDI Beetle

currently parked - 1996 Dodge 2500 Cummins Turbodiesel
Custom cab, auto, 3.55 gears
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Old 06-24-2012, 12:28 AM   #5 (permalink)
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Looking forward to the progress. opcorn:
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Old 06-24-2012, 05:56 AM   #6 (permalink)
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I don't recall your Dodge. If it's covered on another thread, a cross link would be peachy.

Rock on!
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Old 06-24-2012, 06:56 AM   #7 (permalink)
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Skyking,

Will fuel be paid for based on:
a. a pre-established per mile rate, (Ka-ching!)
b. or based on gas pump receipts? (Why bother?)
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Old 06-24-2012, 08:07 AM   #8 (permalink)
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Woody - '96 Dodge Ram 2500 SLT
Team Cummins
90 day: 23.82 mpg (US)

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90 day: 15.1 mpg (US)

TD eye eye eye - '03 Volkswagen Beetle GLS
90 day: 49.05 mpg (US)

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Quote:
Originally Posted by KamperBob View Post
I don't recall your Dodge. If it's covered on another thread, a cross link would be peachy.

Rock on!
It is Woody, right there below my avatar.
The only other thread:
http://ecomodder.com/forum/showthrea...sel-21857.html

Quote:
Skyking,

Will fuel be paid for based on:
a. a pre-established per mile rate, (Ka-ching!)
b. or based on gas pump receipts? (Why bother?)
Based on: the 60 MPH portion is for a job I get paid to do, namely set up a replacement server; the 450 mile 70 MPH part is tentative and more informal
Took me a while to get to the truck. I finished up the rack and need to paint it this morning, did not have hinges, need supplies.
Good news? I have help coming.
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2007 Dodge Ram 3500 SRW 4x4 with 6MT
2003 TDI Beetle
2002 TDI Beetle

currently parked - 1996 Dodge 2500 Cummins Turbodiesel
Custom cab, auto, 3.55 gears
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Old 06-24-2012, 11:06 PM   #9 (permalink)
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Woody - '96 Dodge Ram 2500 SLT
Team Cummins
90 day: 23.82 mpg (US)

Avion and Woody - '96 Dodge/Avion Ram 2500/5th wheel combo
90 day: 15.1 mpg (US)

TD eye eye eye - '03 Volkswagen Beetle GLS
90 day: 49.05 mpg (US)

Mule - '07 Dodge Ram 3500 ST
Thanks: 565
Thanked 458 Times in 297 Posts
Help did not materialize, but I moved the schedule back a day. Design by noggin has morphed several times today. Will return with pics when the skeeters start eating me up
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2007 Dodge Ram 3500 SRW 4x4 with 6MT
2003 TDI Beetle
2002 TDI Beetle

currently parked - 1996 Dodge 2500 Cummins Turbodiesel
Custom cab, auto, 3.55 gears
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Old 06-25-2012, 01:44 AM   #10 (permalink)
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Join Date: Apr 2011
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Woody - '96 Dodge Ram 2500 SLT
Team Cummins
90 day: 23.82 mpg (US)

Avion and Woody - '96 Dodge/Avion Ram 2500/5th wheel combo
90 day: 15.1 mpg (US)

TD eye eye eye - '03 Volkswagen Beetle GLS
90 day: 49.05 mpg (US)

Mule - '07 Dodge Ram 3500 ST
Thanks: 565
Thanked 458 Times in 297 Posts
I wanted to use the template as closely as possible, so I designed a shell with longitudinal ribs. Now to get the shape right
I started by laying a sheet of plywood on the floor and tracing it. There is very little else you can find that is more true and square than a sheet of plywood.

I moved it 4 feet, so I could get a 12' grid drawn.

I moved it a couple more times, ending up with a 6' x 12' grid, on 2' spacing.
I hope to build a tail for the truck and thought I could use the length.
Now I could arrange the sheet of plywood to minimize waste.

Using a printed image of the template, resized to suit my truck, I scaled it to get dimensions at stations, and transfer that onto the sheet. I pulled a tape and also made station lines on the angled plywood.
Now I have marks on the plywood that are 2' apart. I want to draw a smooth curve through these points. I have a fiberglass rod for network wiring, but a 10' stick of 1/2" CPVC pipe will work as well.
I started by clamping the rod at one end over a mark, then bent it across the next and the next, taking time to smooth the curve.






I cut the first one out very carefully with the sabre saw. Since the cut is so close to a rip with the grain, the saw wandered pretty badly.
I got a decent looking curve after a couple of attempts, then used that as a guide. Once again, the sabre saw would not track well.
I ended up setting my cordless circular saw to just barely go through the 3/8" ply, and used it instead.


4 finished curves.


I painted the headache rack with something close off the bomb can shelf.






Installed and bolted in solid.



I clamped a piece of 3/8" ply to the rack, and transfer marked it with a straight edge laid on the cab, and cut it out. It has 1/2" margin for the skin and construction method.


My box lids are one of the challenges. I have to make a door in each side of the shell so I can get into the boxes.

This also makes a big hole in the structure I have to work around.

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2007 Dodge Ram 3500 SRW 4x4 with 6MT
2003 TDI Beetle
2002 TDI Beetle

currently parked - 1996 Dodge 2500 Cummins Turbodiesel
Custom cab, auto, 3.55 gears
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