Howdies!

Definitely needs wings.......

 

Thanks for the links. All great ideas! I would do an aero cap if I had room to store it and didn't spend as much time as I do in my camper shell.

I'm definitely going to look into some spats as my first plan of action!

 

How do you make a quality looking aero cap? I want one but I like my truck to look oem, clean, etc. I really like the one bondo did on ecomodder but I have no idea how to make one look that good.

 

Thanks! I'll keep that in mind!

 

Look at the SUVs and you will get some sort of idea how small they are. Experimenting on their size and location will probably take a few cycles to figure out the best way.

Another possibility is a Kammback setup (similar to the 18-wheeler Trailer tails) on the rear of the camper top that you have. The key will be the proper angle and how you will fasten it to the camper top. Materials you use to make a pattern would be cardboard or Foamular (pink extruded foam sheets) and Coroplast (plastic cardboard) with a frame as your final design. If you have fiberglass experience, you should be able to lay up some glass fairly easily on the Foamular. I have discovered that FRP sheets doesn't do well for impacts at all so I wouldn't suggest that.

Maybe using some of the existing fasteners for the rear glass door. Which topper do you have? Got any pictures of the rear section? You might be able to find a cleat system to install so when you need to go long distances, you can easily lock it in place and be easily removed when you don't need it in place.

 

Unless you have the skill sets or have a buddy who has them who would be willing to show you or help you, it can be very difficult and costly to make your own to that level of finish. How much would you pay to have one? $3000 or more? It would take you a long time (10 years or more) to recoup the cost of an aero cap based on gas mileage alone if you didn't change the way you drive. If you're buying it just for looks, then it really doesn't matter how much it costs or how effective it really is, right?

Bondo's Aerolid (http://ecomodder.com/forum/showthread.php/commercially-produced-aerodynamic-pickup-bed-cap-583.html) is a fantastic product and is one of the toppers I was inspired with on my journey to make my own aero cap. As I understand it, he only made molds for the Ford F-150 and not for anything else for the moment as he's not really in the market to manufacture aero caps but to license his patent and design. I believe he made a clay form to build his mold.

Another company that I found makes a concave topper who claims it improves the aerodynamics of the bed is BAT Industry's The Truck Mullet. I found it interesting they had one on a Tundra on their website but they are only making them for the 2009-15 F-150.
http://www.batindustry.com/

There's a lot to making a "perfect/ideal" aero cap. To get to that level, you would need to make your mold (which means you need to come up with fitted designs or prototypes), prep the mold, set up the gel coat, lay up your fiberglass and resin, autoclave it, remove the parts from the mold, clean up the edges, check fitment, install hardware, and then install it on your truck. It costs a lot in manhours and money to make the mold so to produce a mold for only one aero cap isn't cost effective...so to spread out the costs you'll need to manufacture enough to make it cost effective.

You will need to allow for variances on fitment as you might guess...not every Tacoma truck is exactly the same so adjustments on the mold may be necessary. Then there are the different bed sizes and cab configurations...as well as colors and finishes. It's tough to make parts for older trucks and hope that you sell enough to make it worth your effort and to recoup your investment.

As you might guess, there are a lot of skill sets required to make an aero cap. My aero cap has evolved over the past 7 years as I've learned on materials, structural support, design, mistakes, and a few others. It's been a fun project to play with and to see how much of a difference an aero cap can make. I'm not even past the design phase and I'm not even looking to make more than the one I have. My goals have changed slightly as the years have gone by (aerodynamic, lightweight, removable hatch, front access doors for cab cover, easy to disassemble and store, water tight) and some are tough with my current skill sets.

...and that's why my aero cap looks the way it does...and I have a long way to go before it will get to a finished look.

 

Here's a thread on an older Tacoma if some of you are looking to build your own Tacoma aero cap and need a baseline to work from.
http://ecomodder.com/forum/showthread.php/aerocap-tacoma-pickup-11271.html

 

Here is my camper shell. It is raised up in the back so that probably reduces my aerodynamics and would probably have to make a longer kammback. I do like the idea of those semi truck tails. I wonder if I can make something like that. I have some ideas that I need to jot down later after my day of testing. How do I make one of those teardrop side views of my truck to see the best angles?
I think my corse of action will be side skirts, wheel spats, back wheel covering, and something in the back I want to design!

 

So I came up with a couple things. First is just side skirts, wheel splat, and back wheel covering. Are wheel skirts even necessary at this height?



Next are two back aerodynamic things. I tried to make a teardrop thing but I don't think it will work. Here is that mock up. It would have to be way long and even that probably isn't going to do anything helpful. Also can't really store something like that easily



Lastly I did what the 18 wheelers have with those back tails. However with this, I don't think it will have the same effect as a 18 wheeler because of the size?



Or do you think something simpler with just two sides using the tail gate and rear window would work like this?

 

I don't believe that side skirts and rear wheel skirts are going to do you any good just because of the height of your truck. A full belly pan would probably give you better results...you just have to be careful of the heat build up. I don't have to worry about mine as it's a dropped belly pan and there is ample space between the belly pan and the exhaust system.

I would not do any design that allowed the rear window to be left open as part as your Kammback. You take a chance that exhaust gasses can enter the bed from the rear. Also, that window is very expensive to replace should anything happen to it. Look at all the camper tops being sold with the rear window broken.

The third picture would seem to have the most potential to build. The fun part will be trying to attach it and also designing it so you can easily get access to the bed.

 

I forgot about heat... I'll figure something out. Well I'm kind of glad to hear that I should just go belly pan so I don't have to have the skirts and wheel cover. So full belly pan (be careful of heat), front wheel spats (should I do rear wheel spats too?), and that contraption in the back. Hopefully I can squeeze a little bit more mpg out.

With the back contraption are there angles I should look for or just scale down the ones big rigs have?

 

I just spotted front wheel spats on the newer Tacoma!

I think you might want to come on over to the dark side and join up on www.ecomodder.com and start your own thread. There are many threads on Kammbacks. I think the maximum angle is no greater than 15° with the ideal being around 12°.

http://en.wikipedia.org/wiki/Kammback
http://ecomodder.com/forum/showthread.php/what-best-angle-kammback-13369-2.html#post176591

You can keep the length of the Kammback short so you don't have to worry too much about building a complex support structure like the Trailer Tails have. Thickness can work fairly well to give you that support.

My experimentation with the sides skirts and rear wheel skirts have been rather interesting...the rear wheels are almost super clean! I don't think my side skirts have been providing significant aero...at least I can't find it in my data to prove it.

 

I tried starting a thread there and it never got published. Can you explain that?

 

I joined

I have more questions than answers now haha. Once I am allowed to post pictures that would be great!

 

Nope, can't answer that as I'm just a forum member and not a moderator over there. Give it another shot...tell them I sent yah!

 

I think the minimum number of posts you need to have is 5 or 10 posts before you can post pictures.

Just like any forum, you'll get some members to tell you to search for everything while others will nudge you in the right direction. Welcome to ecomodder and may your quest for better economy take you in the right direction!

 

My air bag spring has arrived! Going to install it on the trailer in place of the rubber puck suspension system. I have to send the fork out to the welder so he can install an extension plate on both sides so it will fit. You can see where the air bag spring will rub up against the swivel housing if I did install it in the dampener housing section.

 

Like your suggestion. 222 mile trip at 65 mph. Took about 3.5 hours. Used half a tank and got 24 Mpgs!!!

 

Great job! You will save about 3 gallons for this round trip alone...maybe about $4 based on your local gas prices?

Now that you have a single point for 65mph, will you try a grill block next? Start from the top of the grill first. It's much easier on my grill since it's divided up in thirds. I initially used pipe insulation and then moved to PVC pipe that I cut and shaped to fit the grill. I painted them black so they would not stand out too much.

Can't wait to see how far you can go with some simple mods and adjustments.

 

100 bucks for some possible MPG gain.
http://www.tacomaworld.com/forum/2n...cover-6ft-roll-up-access-literider-100-a.html

I paid 150 for one recently and during my testing, there was a consistent 1-2MPG gain with it covered vs rolled up. This is not to assume that MPG is the same rolled up vs completely off. I have noticed no difference per tank...