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Vehicle efficiency upgrades: 30+ MPG in 2.5ton commercial truck

Vehicle efficiency upgrades: 30+ MPG in 2.5ton commercial truck
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[note:  new video has been added on step 1!]
[note 2: Most of what I write isn't relevant to Instructables.  My main blog is here: biodieselhauling.blogspot.com]


Go 50-100% farther on a tank of fuel.

Due to its size and weight this truck is considered a commercial vehicle and is exempt from even light-truck CAFE standards. Even so, with the modifications I have made, I am getting higher mileage than CAFE standards for 2009 cars.

I read an article in Mother Jones Magazine about Wayne Gerdes, mileage champion, and was inspired. I have read that people tend to get between 10 and 16mpg on average in the same truck I have. I was getting around 15. After the mods described here, on a recent tank I got 30.28mpg.

The best thing to do is to not drive at all. Ride a bike, take the train, carpool.
If you do drive, buy the absolute smallest car you can. If you only need a big vehicle occasionally, rent one.

I bicycle or use my 70mpg 250cc motorcycle for personal transport, but my truck still gets a lot of miles, so I wanted to make it as fuel efficient as possible.
I use this truck for work, moving up to 3 tons of soil or broken concrete, entire 1 bedroom apartments worth of belongings (including furniture) in a single trip, etc.
I also need something with enough power to move my 7500lb RV trailer (which is also my home - a very efficient way to live: I use as much electricity in a month as the average American home uses in one day)

Most of these steps could be done to any vehicle, increasing mileage from 50% to 100% or more.
 
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Step 1The cheapest, and most important step

The cheapest, and most important step
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Modify driving habits

Single most significant difference, in any vehicle: "Adjust the nut behind the wheel"
(Drive more efficiently.)

Stay at (or below) the speed limit.
(Remember, you only save 7 seconds per mile going 75mph instead of 65mph, but stopping distance and wind resistance increase exponentially; twice as fast = 4 times the force)

Accelerate gently (Keep RPMs low whenever possible)

Never accelerate towards a stop light. (Every time you brake you are wasting momentum)

Never idle. A popular misconception is that it uses more gas to start than to idle. This was true of older (carbureted) engines. This is not true of modern (fuel injected) engines.

More advanced techniques include actually shutting off the engine and coasting as often as practical. (This can change the feel of the brakes and steering, see step 4)

(PLEASE READ the entire instructable and all the comments before commenting about how dangerous it is to coast.)

NOTE: many automatic transmissions can be damaged by coasting with the engine off.
To find out if yours is one of them, consult this list: http://www.motorhomemagazine.com/dinghytowingguide/
If you have an automatic, and your car is on the list, you can shut the engine while moving.
If it is not, do so at your own risk. You may still benefit from shifting into neutral (engine on) when coasting downhill or towards a stop, depending on whether or not your car has automatic deceleration fuel cut off (DFCI) built in (many newer cars do).

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379 comments
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Mar 5, 2012. 11:19 AMInswitch says:
Doubling mileage, not too shabby.

On octane, it's best to try 87 and 93 in your vehicle and do a 5 tank average of each to see which gets mileage. A blanket statement of the car being made for 87 won't benefit from 93 is not a good one to make. If tuned for the higher octane (advance timing 2-3 degrees) you may find that you get enough better mileage off 93 to more than offset the added cost. More modern, computerized vehicles have multiple octane tables that do this automatically. When the engine is started it will try the high octane table, if knock is detected it will revert to the low octane table. This is fact, I have software that allows me to reprogram my computer (EFI Live) and have altered both tables. Remember that the OEM has their own formula for setting up the engines that covers the widest range of uses, and their formula isn't necessarily the best one for your needs. I'd also recommend trying this with different brands. I have had vehicles that will get better mileage with brand A than brand B, but a second vehicle will get better with brand B than brand A, and still others that didn't care what was in the tank. I've even had two otherwise identical vehicles prefer different brands, so this needs to be checked on a per-vehicle basis. Remember when testing that fuel formulations change in spring and fall, and this will impact efficiency.

If you don't mind digging into the engine, a camshaft swap will also help. OEM cams are a balance of power, fuel economy and emissions requirements. A cam that is weighted more towards fuel efficiency would benefit. It may no longer pass a mandated pollution test, but those tests are set conditions. A vehicle that uses less fuel per mile is going to be emitting less pollution per trip.

I tried the acetone. It only worked for 1 tank, after that saw no difference. 1 tank is not enough to say it helped, so in my experience acetone does nothing for you. Once again though, different vehicles will act differently, but it was really a big pain in the backside making sure there was always some in the car.
Mar 14, 2012. 8:14 AMcbckidatheart says:
Great article, I have a 1994 pickup that I want to try a few of these things on. Something that should be mentioned is that even though new trucks can get up to 25 mpg now, it cost so much money and energy to have a new car built, shipped and purchased. Which is hard on the environment, yet there are thousands of cars going into the yard each year that only need a few parts. Current cars on the road longer and making them more fuel efficient is a great way to start an eco friendly movement.
Jan 27, 2012. 8:57 AMearthwindwater says:
Thank you for explaining the Alt delete!
Dec 20, 2011. 1:20 AMdragonriot says:
I'd really like to know how much this guy spent on "Converting" his truck over time. I drive a 94 Yukon 6.5L Diesel, and I know that my current 17mpg average would go up to 36mpg with a Cummins 4BT swap.
Jul 25, 2010. 4:53 PMRportal says:
Driving slowly is illegal. It is called impeading traffic and you can be cited. Just so you know.
Dec 20, 2011. 1:14 AMdragonriot says:
Totally not true about posted minimum speed limits. Wisconsin has a 45MPH minimum speed limit on all Interstate Highways (I-94, I-43, etc) and it's not marked anywhere on any highway sign anywhere in the state. It is the same whether you're on a 65mph zone, or a 55mph zone, 45mph is the minimum. Of course, if the MAX limit is lower, then the minimum limit is lower as well, but there's no point in going 35 in a 45mph zone.
Oct 17, 2011. 11:03 PMfreddysserpent says:
actually it is up to police descretion as to what is an impedment of traffic (which you can be charged for) and their working model is different state to state but if you stay within 20% of the limit(depending on conditions) you won't have any problems. Oh by the way you can be charged for driving at the speed limit as well if the conditions are bad. It is called negligent driving (for not adjusting to the change in conditions). Unfortunatly if you are charged with either offence it is difficult to fight in court as I know from personal experience ( I was lucky that I hold a raceing license as well therfore my knowledge and level of expertese was considered better than the police officer's involved )
Nov 4, 2011. 9:25 AMvincent7520 says:
Back to hippies days ! … Far F… Out !!!!…Get rid of everything ! …


:D :D
May 12, 2009. 1:01 PMswoopsdad says:
Actually, having been in the automotive industry for almost 20 years I feel the whole tonneau cover, tailgate up or down aerodynamics issue needs to be put to rest at last. When the box is empty the most fuel efficient state is without a tonneau cover and the tailgate(solid) in the up position. This is because the truck has a bulit-in laminar airflow to it when empty and in this configuration. Simply put, this means that the airflow created in the bed of the truck acts like a cushion to keep the airflow from the front above the bed until it gets to the rear bumper. By putting a toneau cover on(or leaving the tailgate down) it disrupts the laminar airflow creating downwards pressure on the bed(or rails) of the truck. This results in a higher drag coefficient and therefore higher gas consumption.
Sep 4, 2011. 1:39 PMpddonovan2011 says:
You are correct, there is only one modification that could be done that would make the 'tailgate up/bed empty' mileage even better! From the top of the tailgate to the bottom o the lowest part of the bumper make a perfect radius or half dome on its side. Create round Plexigalss or Lucite covers with this same radius to cover the side taillights and you will complete the laminar flow on the tail will Actually be pushed along at highway speeds!
Jun 17, 2011. 2:45 AMzolar1 says:
This would be vehicle specific. I have a 2009 Ranger. Tailgate up - 18-20MPG.
Tailgate down - 24mpg.

Oh, Mythbusters has been caught outright lying about a great many things. And intentionally skewed results from a lot of other things as well.

Great entertainment, but please do not believe anything they say. They do it for entertainment value only.

BTW, how come no one has done an experiment with the tailgate removed?
And another one with those cargo straps for a tailgate?
Sep 4, 2011. 2:23 PMpddonovan2011 says:
I HAVE, how's this for vehicle specific!
2003 Chevy S10.
I have an iPhone App that reports real time MPG via the OBD2 port.
No tailgate, 29.8 mpg!
With tailgate, 30.3 MPG!
With hard Fiberglass Bed Cap 30.7 MPG!
With thin Plastic vehicle specific,'Cab-hi Shell, 30.6 MPG.
With the tailgate and the Shell Hatch removed, 30.8 MPG.
With a round tail-cone installed and sealed to the rear of the bed and shell, lots of duct tape!, 31.2 MPG.
These tests were made at the same time, during the same commute, down the same highway and reflect the average collected during a FULL WEEK of commuting for every result!
The Saturday before each of these weeks, the battery was disconnected, overnight, to reset the computer in the truck. This way the computer relearned the trip for that week. The ONLY modifications made were to the rear of the truck.
I have not yet tackled the front of the truck! I could change the grille, the head lights, use clear tape to seal any 'dirty' gaps. remove the windshield wipers. I could really go nuts with this stuff! But the truck has the 4.3 V6 and Over-drive Automatic. I KNOW I am doing damned good with the MPGs I am getting!
Aug 14, 2011. 2:07 PMFuzzyBearGeek says:
omg. Are you one of those paranoid type people? They do it for entertainment porpoises only? Wow. Floored.
Do you believe dinosaurs didn't exist too?
Aug 14, 2011. 9:24 PMzolar1 says:
LOL. Of course dinosaurs existed.

But Mythbusters is strictly an entertainment show, nothing more.
Fun to watch them blow up stuff.

And no, I am not the paranoid type. I am more of a doubting thomas of sorts.

If I cannot recreate their experiments with the same or very similar results, then their show is a farce.

There have been complaints with them about some of the things they show.

Maybe googling 'mythbuster lies' could be of use?
Feb 6, 2011. 11:40 AM13blue says:
There was a great "Mythbusters" on this that proved the same thing. Empty bed with the tailgate up was the way to go. Also the windows up with the air con on is more efficient that with the windows down. I had to adjust my driving for both of these.
Aug 14, 2011. 2:08 PMFuzzyBearGeek says:
I love your brain. :o)
Jun 27, 2009. 3:14 PMkikiclint says:
I have been turning my truck off going down hills on the free way. I can definitely tell a difference when I have my canopy on. It slows me down. With it off I have to keep my foot on the breaks to stay in the speed limit.
Jun 16, 2009. 1:59 AMjoeofloath says:
That is true of newer vehicles, but remember when this truck was designed, aerodynamics weren't even tested. The first regular (IE not a race/performance car) car to really be looked at from an aerodynamic perspective, as far as I know, was the European Ford Sierra. In older trucks, It would be more efficient to keep the tailgate up and use a tonneau cover.
May 16, 2011. 2:17 PMbahi says:
I admire you work and effort. I wish I could do the same here in Spain, but such radical modifications are illegal.
But one of the most important things we all can do is driver slower, it saves fuel and the most important thing, lives.

Max speed has been temporary lowered here from 120km/h to 110, and most of the people are raging against it, it's sad to tell, but most of the people don't really care about Self-sufficiency, environment or other peoples lives...

Anyway thank you for your great instructable.


p.s. I have a pickup too but I also ride a 250 bike or bicycle to work :)
Apr 11, 2011. 2:00 AMthisiskaleb says:
Will switching to premium gas help? I've heard that it burns more efficiently but doesn't work well with older engines. My old Corolla lost a good bit of mileage when I tried switching, but come to find out it was on its deathbed anyway (500 miles a day delivering pizzas didn't help.) Now I'm driving an '86 4Runner with a rebuilt engine (about 18,000 miles on it) and wouldn't mind some insight on the topic and what factors come into play when burning a higher octane fuel. And btw, GREAT INSTRUCTABLE!
Apr 7, 2010. 9:38 AMjustinRgray says:
I like  your approach to saving the environment: make you car or truck so annoying to drive at any given point you will just give up and ride a bike.
   LOL
Nov 4, 2010. 1:19 PMmorbidmx says:
your way of seeing life and help actively to the conservation of our planet is commendable. the search for maximum efficiency of resources, is so foreign to today's lifestyle, which to most will seem ridiculous changes you made to your truck.

However, it is justified and is nice to see the commitment that you have acquired through the use of your resources. Not only have you changed your vehicle, your habits and customs also

will try to do the same with my truck
May 20, 2010. 11:26 PMnerys says:
I agree. Makes it a lot more fun. Game Like more competitive. Even entertaining.

Got pulled over tonight (a light was out) combined with me doing 45mph in a 50mph I guess I passed their "itch" thresh hold and the out light gave them the probable cause they needed to pull me over.

No problem all paperwork in order etc.. but on mentioning I was driving slower to save gas (there was no one behind me) he said got other things to worry about than a little gas.

I came back with $1100 in gas. He looked at me and said what? I said slowing down 5mph saves me $1100 in gas a year.

Just look at me oddly with shock :-) I said I drive 40,000 miles a year. a 3 mpg increase over 40,000 miles is about $1100 a year. (actually $1066 but $1100 was close enough)

He said. Oh and went back to check my papers.

I bet he checks his mileage this week :-)
Jul 4, 2010. 8:21 AMJoenavy85 says:
That's what i do, i'll drive home from my friends house and try to get my average MPG as high as i can. it's about 25 miles and is a mix of city and highway driving, but unfortunately the highway portion doesn't have many semi's but it does have the occasional stoplight which gives me an excuse to coast. I coast in neutral up to every stoplight and i stay in neutral until the light turn green (no different than having a stick shift and waiting to put it into first). on downhill sections i "pulse and glide" to the exit (about 1.5 miles) and coast up the off ramp to the light in neutral. Last night i averaged 25.2 MPG from her driveway to mine, and that was with having to completely stop at 6 stoplights, one of which was on the highway.
May 21, 2010. 9:19 AMnerys says:
Oh heack yes :-) same name :-)
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Author:JacobAziza
I am an ordinary guy. Except that I live in an RV, drive a 250cc motorcycle, have a truck that runs on bio-diesel, am vegetarian, and have had almost 30 jobs in 10 years, including armored truck drive...
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