My T-100 aero cap...
 

Over at ToyotaNation...I documented my build of my T-100 aero cap. :D

Here's some different looks of the hatch configurations... ;)

Closed up with a proposed boat tail length...
https://www.fuelly.com/attachments/fo...616bc67b18.jpg

Standard cap height...offers a great view when backing up!
https://www.fuelly.com/attachments/fo...044ff1766d.jpg

Rear view...
https://www.fuelly.com/attachments/fo...d4af07fe09.jpg

Wide open...
https://www.fuelly.com/attachments/fo...d1327c6b94.jpg

Rear view...
https://www.fuelly.com/attachments/fo...125d3d4fce.jpg

Keep in mind that I designed this strictly fer aerodynamic testing...not fer security. The hatch is easily removed fer tall items just by removing 2 screws. My other goal is to be able to easily disassemble the entire cap just using one person. :D

I have to pins to keep the hatch from opening on it's own when I'm driving down the road. It also keeps people from opening the hatch but they can always open the tail gate since it's not lockable. :(

Estimated costs is probably around $40 since the coroplast was free and I'm reusing most of the wood/hardware from my first belly pan project. Estimated weight is around 40-50lbs? Not exactly sure though... ;)

Re: My T-100 aero cap...
 

Looks great!

I wish I could come up with free coroplast that large.

Re: My T-100 aero cap...
 

The hatch is basically made from 3 sheets of 4x8 coroplast. The two bottom sheets overlap each other like a hand fan...close together at the top (narrow) and then spread out at the bottom (wide). I have a third 4x8 sheet that covers that up...makes it more stable. :D

Re: My T-100 aero cap...
 

It survived the heavy rain last night...just a little bit of water in the right rear corner of the bed. I'll have to put some camper top foam on the sides where the hatch closes on top of it. I hope to have the backside buttoned up soon with some plexiglass... ;)

Here's what the cap looks like as I prepare to go on a trip up North...
https://www.fuelly.com/attachments/fo...34fc06cd27.jpg

Re: My T-100 aero cap...
 

Buttoned up the rear with some Lexan I got at Lowes and headed up North. First tank from Houston to Ardmore was 25mpg cruising at 65mph. Second tank was filled with some ethanol free gas and yielded 28.86mpg cruising at 65mph. Weather was rainy and temps were in the upper 40's. I was carrying about an extra 400lbs of passengers and their luggage...this was above my standard tool/gear load out. :D

Re: My T-100 aero cap...
 

Trimmed up the front edge...
https://www.fuelly.com/attachments/fo...51735783de.jpg

Re: My T-100 aero cap...
 

Gas struts are mounted to the hatch!! :D

https://www.fuelly.com/attachments/fo...227157c764.jpg

Re: My T-100 aero cap...
 

Put in metal straps to hold the hatch open at the standard camper height fer those times I need the hatch open but not all the way open. When they're not needed...I just swivel them out of the way. I use the same pins to keep the straps in place as I do when I lock the hatch down. :D

https://www.fuelly.com/attachments/fo...6171f2f86d.jpg
https://www.fuelly.com/attachments/fo...d6e8deeebe.jpg

I guess I could make some inserts to eliminate the gap between the hatch and the sides... ;)

Re: My T-100 aero cap...
 

Can you post your MPG numbers for both before and after the modifications so we can know how well this worked. If it works I may try it myself. Thanks

Re: My T-100 aero cap...
 

I've documented my fuel mileage in my fuel log...
https://www.gassavers.org/garage/viewgaslog/1723