funny this topic should come up today. i was just calculating the frontal area of my car to plug in to some drag formulas.
in my opinion, after driving style, aero mods are the area where the largest gains in efficiency can be made for the least money spent.
if you haven't read about Phil Knox and his aero-modded Toyota T-100 pickup, you should. a real-world example of how he increased his hwy mileage by 28% without fiddling with the engine one bit.
free fuel riding on the wind - EV World
admittedly, it's relatively easy to improve a pickup truck's aerodynamics, because they suck to begin with. improvements to a modern sedan or hatchback will be less dramatic, but it can still be done.
i tested 2 aero mods on my firefly late this fall and they netted me a 5.7% increase in hwy mpg in repeated, controlled testing:
Testing grille blocking & wheel skirts: +5.7% improvement - metrompg.com
aero mods will be my main focus next spring & summer. still on my list:
"permanent" mods:
- full under tray
- gap fillers in front wheel wells
- ride height lowering
- deflectors ahead of each tire
"experimental" mods:
- a removable lightweight boat-tail for hwy trips
i expect the "permanent" mods (in addition to gains already realized from rear skirts & grille blocking) will net a total hwy improvement of around 15%.
the boat tail idea is the least practical, but the rear of any vehicle is actually where the biggest gains are to be made (reducing the wake area).
svoboy: phil also owned a 1st gen crx which he aero modified extensively (extended the rear of the car by 12 inches so he could continue the taper to reduce the size of the following wake). he both increased his top speed (tested on the salt flats) and his hwy mileage dramatically.
there's a yahoo group (maxMPG) that focuses pretty heavily on aerodynamic discussion:
http://autos.groups.yahoo.com/group/maxmpg/