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Bob Sliwa's AirFlow Truck Company Creates World's Biggest Aerodynamic Hot Rod

17 Feb 2011

This view shows the various plumbing of the completed air induction system, the charge air system, the air conditioning system, and the coolant and cooling systems.

Like other inquisitive young kids that grow up to reshape the world as we see it, Bob Sliwa also began his intimate relationship with science and physics, by disassembling his toys just to see what makes them whiz and whirl. But, when he sat down to design and then create a brand new Class 8 tractor trailer rig with advanced aerodynamics, extraordinary fuel savings, and a very low emissions profile, he ended up revolutionizing over the road trucks.

The 2011 AirFlow SuperTruck, the world's biggest hot rod, is scheduled to be rolling by this spring.

Sliwa founded the AirFlow Truck Company in 1983 and his vision to substantially lower the cost-per-mile operating cost for fleet operators and owners of rigs, is destined to become reality when he unveils his first working prototype of AirFlow's second-generation design. Sliwa recently agreed to talk with us about what he calls the world's biggest hot rod.

Having seen the concept drawings of the truck, we have to say that in comparison, other rigs look like dinosaurs. How and when did this idea come about, was it swirling around in your head first as you drove trucks yourself?

"Thanks for the compliment. Actually you got it just right. The idea started swirling around in my head when I first became an owner-operator in 1980. Soon after buying my first cabover tractor 18 wheeler, I then realized how poor the fuel mileage of existing equipment was. So right then, I decided to improve the efficiency and the fuel mileage, using my prior drag racing experience."

Shown here on top of the Cummins ISX is the new air induction system, and the new Heavy Duty Air Filter assembly from K&N Filters.

At first glance your truck resembles a European/Asian Bullet train somewhat, how did you come up with the "airflow" design and how much wind-tunnel testing was done, and what sort of measurable drag and fuel reductions do your results indicate?

"The current AirFlow 2011 SuperTruck design is actually a morphing of a Kenworth T2000 truck, into a more aerodynamic design, as opposed to starting with a "clean sheet" design. So many design compromises had to be made. It would have taken many more years, and tens or hundreds of thousands of dollars more, to do a clean-sheet prototype."

Here is a close-up shot of the detail on the left side of the Cummins ISX.

"We had great help with the SuperTruck design from our CAD and CFD designer, Jeremy Singley, of Jeremy Singley Industrial Design. The AirFlow rig has never been out on the road yet, so we have not done any actual wind-tunnel testing. All of our aerodynamic testing has been done via computer with software provided by one of our Partners, SolidWorks. SolidWorks provided the Computational Fluid Dynamics (CFD) FloWorks software that we use to tweak the aerodynamics. The CFD software is analogous to a virtual wind tunnel. Our FloWorks CFD software says we have 326 lb ft of drag, which is a 45% drag reduction over a stock Kenworth T2000 pulling a stock trailer. This translates to an approximate 25% fuel savings."

In general terms, just how much research has gone into the overall concept, and have you found that it continues to evolve as you get further into the development?

"The research has been ongoing and evolving to some extent for over 25 years now. I always knew I wanted to build what is called a 'conventional' tractor, as opposed to a 'cabover' tractor. The basic difference is that a conventional tractor has the engine in front of the driver's compartment, and in a cabover, the drivers compartment sits over the engine. We have only ramped up research and development in the last two years with this new project and the prototype. Yes, the design and the details do evolve daily. When we add one new piece it sometimes affects many other pieces of the puzzle. Oops! I mean the prototype."

How many people are currently working on the project with you?

On a day-by-day basis, it is usually just myself, as a one-man project. My best friend helps out with the actual build on some Saturdays. And our CAD/CFD designer works on CAD details, or aerodynamic tweaks, on contract assignments for us. But, I estimate that I have done 98% of the work of the AirFlow Truck project myself. From contacting sponsors, administering the web site, buying parts, building custom parts, and the actual prototype truck build itself. Six days a week for the past two years.

Are you aware of any other truck design projects along the same lines as yours?

"Not to this extent, at least, none that I am aware of. Many OEM's are trying to get better fuel mileage and lower emissions through various, and what I consider questionable, techniques. But basically, I feel that the large truck OEM's are at least 30 or 40 years behind the times with their designs, even though they all check out the AirFlow Truck web site on a regular basis. Volvo Truck North America has been to the AirFlow Truck web site over 100 times in the past two days alone."

Tell us a bit about the engine design and how did you decide to go with the K&N intake?

"Other than the redesigned cooling system and drive belt system, and the custom implementation of the new K&N Heavy Duty Washable Air Filter, the engine is basically a stock Cummins ISX 450 horsepower diesel engine."

"We have done some modifications to the ISX to reduce parasitic horsepower losses. These include removing the belt-driven A/C compressor and installing an all-electric A/C compressor, removing the 40# cooling fan hub, and adding 45 quarts of 5W40 synthetic motor oil."

"Being a former amateur drag racer, I have been familiar with K&N Filters, and their sterling reputation for quality products, for over 40 years. So when K&N recently introduced their new K&N Heavy Duty Washable Air Filter, and when K&N told me it has lower restriction than the OEM filter, I knew we had to have one for the project."

Are you finding a lot of support for your concept from the trucking industry and other truckers?

"We have received overwhelming support from truck component and equipment manufacturers, especially the ones who have a newer version of technology than previous versions of the same component."

"We have over 20 corporate partners, and without their magnanimous support, we could not have even begun a project of this scope and magnitude. Again, the prototype has never been out on the road. But I would imagine that the old-school truckers will not appreciate the design and would rather actually drive, or own a square truck. The businessman truckers, the ones who are in it to make money and not just interested in buying shiny chrome do-dad add-ons, will appreciate the design. They will also appreciate how much fuel and money it saves."

Ideally, how would you see this project playing out, meaning would you like to go into full-scale production? Also, have you given any thought to developing particular components of your truck to increase the efficiency of existing rigs, such as creating bolt-on airflow body parts or engine components?

Unless we are able to obtain adequate funding, this will be the only version of the AirFlow tractor. You hit the nail on the head when you said 'developing particular components of your truck to increase the efficiency of existing rigs, such as creating bolt-on airflow body parts or engine components.' That is exactly what we have in mind. Specifically, trailer skirts, which have now been required by CARB. Although just in case funding is available, we have already designed a 2015 next-generation of the AirFlow rig, and we actually have a 29" long plastic model of it."

Find K&N products for your vehicle using the K&N application search then use the K&N dealer search to find a K&N dealer in your part of the world.

Phil Cocuzza Racks Up Success in Business and Racing Using K&N Products

17 Feb 2011

Phil Cocuzza's 2010 Chevy Cobalt

Like so many who personally participate in various forms of motorsports, Phil Cocuzza quite elegantly intertwines his business of thirty years, California Muscle Cars, right alongside his successful drag racing career.

NHRA National Event Racer Phil Cocuzza

Cocuzza currently wheels a 2010 Chevy Cobalt equipped with a 398 cubic inch power plant in NHRA Competition Eliminator ASMA class and coming into the 2011 season, he is presently an NHRA National Record Holder.

Racing since the mid-1960's, Cocuzza has competed in his current category for nearly the last two decades, during which time he has set twenty-four NHRA National Records in numerous classes with his various cars, not to mention the many "Best Appearing" and "Best Engineered" accolades. For 2011, he looks to build on those successes while remaining a little closer to home.

2010 NHRA National Record Holder Phil Cocuzza

"We are for sure going to do as local as we can," Cocuzza explained when asked about his plans for the upcoming season. "Maybe Vegas the week before Pomona, but Pomona [National] for sure. We are really going to have to look and see, but we should be out about eight races this season."

"We would have had more NHRA National Events scheduled this year, but NHRA took Comp Eliminator out of three west coast events for 2011," he continued. "That really killed us. They pulled us out of races right here in our backyard."

Cocuzza has plenty to keep him busy in-between those events at his bustling shop in Acton, California, just thirty miles north-east of Van Nuys, where they offer everything from custom engine work to complete vehicle restoration. Many of the same products that he uses in his national record setting race program are also used in his customer's jobs, including offered from K&N Engineering.

"We have been using K&N products for a million years," chuckled Cocuzza. "Not only in our racing program, but in the engines that we build for our customers. Not just the K&N oil and air filters, but now we are also K&N's Racing Glue."

"The Racing Glue line has all types of products for various applications," noted Cocuzza. "There is a thread lock, and different sealants. They make a gasket compound, which is their own formulation of a silicone. There is a thread sealer in three different varieties of hardness, depending on what you need it for. In the kit there is a soft and a medium thread lock and then there is a full hard thread lock, like if you were putting in flywheel bolts or something like that."

"It's all really good stuff," he added. "It's a nice kit."

Again in 2011, K&N is offering contingency for Racing Glue Kits for sportsman competitors at NHRA National and Divisional events, in addition to the Oil and Air Filter programs. For more information on all the programs available visit - https://www.knfilters.com/contingency/NHRA.htm

Look for Cocuzza, and his wife Barb, as they will be hitting the 2011 NHRA race trail in the weeks to come in their K&N Racing Glue clad Cobalt.

Find K&N products for your vehicle using the K&N application search then use the K&N dealer search to find a K&N dealer in your part of the world.

Mick Høy Motorcycles Around the World with K&N and Discovers Himself

15 Feb 2011

Camping in Togo after making nice with the police chief.

It can be argued that the only true reality is the immediate "Now." The past is simply a collection of trace memories of a now that came and went, and that our preoccupation with the future is merely an expression of an increasingly distressed and uneasy social disorder akin to neuroses. Thusly, few occurrences in an overall life experience, brings the need to live in the now more into focus than a sustained commitment to the road, travel not for the sake of destination, but rather for the journey. Wanderlust has been described as an overwhelming desire for, or the impulse to wander, or travel and explore, not only the world outside, but the one that exits inside each of us.

Mick Høy says that K&N has made it possible for him to continue his journey discovering this amazing planet.

Mick Høy is 32 years-young, and two years ago he lived in his native Copenhagen, Denmark. Then Høy came down with a tremendous case of wanderlust, and frankly, he hopes it's just a little contagious.

"Right now I am in Santiago, Chile, for some months. I'm working to be able to continue my travel. Nice to talk to a fellow motorcyclist that understands and can put himself in the same place as I am," remarked Høy.

"Going on this journey, it is for sure a decision I would never change. It has been both extremely giving, but also hard at times. Yet, looking in the rear view mirror, I can't, and won't change anything! Today, I still feel this is what I had to do, at least one time in my life and I keep fighting to keep being on the road, instead of taking the easy option, and going home when the money has run out."

The end of the world Ruta 3 in South America.

Høy left his home in Denmark in May of 2009 and he has traveled anything but the path of least resistance ever since. He has traversed around too tightly wound roads that curved only to the next adventure, sludged on during floods, he's been rocked and shimmied by buffeting winds, and persevered through choking sand and dust, throughout 30 countries, on three continents. He's been mistakenly arrested, hungry, lost and robbed. He has already journeyed nearly 40,000 miles, and has no immediate plans of throwing in the towel anytime soon.

Stuck in the Nigerian sand.

"I am riding a 15-year-old Honda VFR 750 with 127,000 Km (78,000 miles) on it, which has been through some of the hardest and dusty environments on the planet, such as Western Sahara on my way down south along the west coast of Africa, and not to forget the windy and sandy Ruta 40 in Argentina. During this remarkable journey around the world, I have been riding with a K&N air filter, which for me was ideal, as I could clean and re-use it again and again. After my great experiences with K&N air filters, I have decided to use their oil filters as well, and look forward to riding with these in the future. Throughout my travels K&N has continued to supply me with incredible help, keeping me on my bike, and on the road."

"For me the most important thing about travelling is not so much the places you go, but the people you meet. They give you the memories for life! And, I can thank K&N for making it possible for me to continue my journey around this amazing planet."

No man's land between Western Sahara and Mauritania

For Høy, the decision to travel began taking shape about three years ago, that's when he saw two motorcycles from Argentina parked outside his apartment. The bikes belonged to Elke and Gustavo Cieslar, a couple on a journey from Buenos Aires to Sydney, Australia. Høy followed and supported the couples exploits on the internet from 2006 to 2009. "During that time I started playing with the thought of doing the same thing," said Høy.

The decision to leave his job as an aircraft mechanic/technician, material planner and supervisor, wasn't an easy one, "But now, I feel this is the best choice I have made in my life," he adds. "I sold everything I had, my apartment, all my furniture, and even my car.

Police chief of Togo.

For me it is not important to own a big fancy car, or live in a huge house. I won't think about any of those things on the day that I die. What I will remember is my family, my future wife and kids, and this journey. During my trip I also hope to be an inspiration for others to do the same - to go and see the world, and meet its wonderful caring people."

"Life is always about the choices we make - a great career, a big house and car and family, or a journey around the world - it's there for us to decide." And Høy believes with all his soul that his choice to undertake this adventure will prioritize and put into proper perspective all the rest of the choices he will still have to make.

He says, "What is important right now is to keep going, even though the money has run out. My money ran out in Ushuaia, my credit cards are closed. Many people would have gone back home by now.

Road to Angola.

If it hadn't been for great friends in Santiago (who offered him a job), all the support I've been getting around the world, this would have been the end for me. But, I've learned that if you keep fighting for what you believe in, whatever your dreams are, then there is always a solution of some kind just around the next turn. And everyday I'm reminded that I did the right thing. I have always been good with my hands, and most of all I love big projects, like the journey I am doing now. It's what keeps me going."

Høy says he never asks his parents back home for money and that his mom would rather see him back home. "But dad understands me much better, and I think he could see himself doing the same thing, if he had made different choices in his life."

"Today it is very easy keeping in contact with people, we have the Internet and Facebook, so I am keeping in contact with most of my friends back home, even old colleagues, but yes, there are a few things that I don't have so much contact with anymore. I don't own a watch, and sometimes I don't know even which day it is. For me it is not so important. I like staying in places for a while, if I meet people that I feel good with. But, once things become too routine, I long for the road, and being together with my fellow travel companion, my VFR."

Buying fuel on the side of the road.

"Believe it or not, but one of the biggest highlights lately was getting a job as a waiter in Santiago. I don't earn much per day, and it is a long day of working, but I feel proud by earning a few quid to help me stay here. It is a good contrast after you have been travelling for a long time. It is not only about the money, it is also about not forgetting what life is, and that one can't live like it is vacation forever. For me it would not be fun doing this journey without working. And this journey itself is a work. To keep traveling I need to find new sponsors, but I also know I need to do something for them. No one gets a free ride. I get emails for people and friends back in Europe saying that I just have to tell them if I need something. I never do though, it is against my nature. If people want to help me, it will have to happen without me asking for it."

"Of course there are days I could have done without, as the day I was taken to the police station in Togo, after I made a rather unsuccessful camera recording of the president coming by in a convoy. It turned into a dodgy experienced first with the police yelling at me that I had two options. Pay my way out of it, or a visit to the prison. I asked for the condition in the prison and if they would give me food and something to drink, as I hadn't had much to eat for a couple of days."

After seeing the grim conditions Høy was traveling under, his messed up clothes and boots with gaping holes, the police captain realized it was all a big misunderstanding. "We ended up as good friends and I left happily, with a picture of the captain sitting on my bike and a visit card from him stating that if I should get into further problems to call him."

Anyone have a snorkel for a VFR?

Høy also experienced some bad mojo while staying in Rio Grande, with some friends, working in their shop helping fix cars. The room he was staying in had gotten broken into and his motorcycle jacket with everything in the pockets got stolen. "Luckily they didn't look underneath the bed where I had hidden my money and passport," added Høy.

Yet another time in Angola he got his motorcycle stuck in mud and water. "I was afraid water had entered the cylinders, but it turned out only my wire harness to the starter got soaked. Two locals came by and helped me push the bike out. Five minutes later we were sitting and drinking tea and eating biscuits while the VFR was drying out. A journey should not be perfect, there has to be some conflict, some bad luck to give the journey contrast."

"Africa and South America are completely different from what I thought, and from what people in Europe think. Of course there are very poor people on both continents, but life can also be good. I saw that in Africa when I got invited to spend the night underneath the stars with locals in a small village, while we eat a chicken they slaughtered because of their guest. They didn't have much, but life was nice. It is another thing I found out about with my life. I like it basic, sitting around a fire at night, maybe by myself, or with friends. That is a fantastic feeling, and that is life for me!"

"I have been almost two years on the road now. My dream is ten years or more. When I look on my map and where I have been, I can only say that I still have a long way yet to go, but I like to go slow and feel the places and the people where I am. I hate having plans of where I have to be tomorrow, or next week. That is the answer to why I travel alone."

"The last thing - I get a lot of feedback and responses from not only people in Denmark, but the whole world that is following me from the side of the road. I think they enjoy this trip because I write very open about my travel, what I feel and what I do. I don't cover anything. Sometimes I can be a rebel, but without hurting people. I respect people where ever I go. But I tend to keep my site (Facebook) without censorship and for some it can be provocative. But, people get the naked truth when travelling with me!"

Find K&N products for your vehicle using the K&N application search then use the K&N dealer search to find a K&N dealer in your part of the world.

Best In The Desert Quad Pro Champion Danny Prather

15 Feb 2011

2009 & 2010 Best In The Desert Quad Pro Champion Danny Prather

Danny Prather started riding atv's at 3 years old, a time when most of us are just learning to ride tricycles. Growing up going to the desert with his family and watching his Dad and Grandfather race desert races instilled a passion in young Danny for off-road racing. His dad, Scott Prather, raced atv's and Danny managed to convince him at age 15 to build a 250r fourtrax out of some spare parts. From there they went racing and won a few local AMA district 38 desert races. At 16 Danny raced the Baja 500 with Greg Row and earned a second place finish; which is quite an accomplishment for a 16 year old. Ever since that great finish, Danny told us "I have been drawn to off road racing and the fun family atmosphere at the races."

ATV rider Danny Prather

Danny had a long list of wins and championships since age 16 including 2006 & 2007 SCORE Overall ATV and Class 25 points champion, 2009 & 2010 Best In The Desert Quad pro champion, and a bunch of AMA District 38 desert racing wins. We asked Danny to name a few of his most memorable moments and he said "In 2003 I teamed up with Mike Cafro and Temecula Motorsports. We raced together for 6 years racing in SCORE Baja races as well as Best in the Desert races. In 2006 with the support of American Honda we won first overall atv in the SCORE Baja 500 and the next 5 consecutive races including 2 Baja 1000's that were point to point down the entire Baja peninsula."

In 2006 Danny's teammate, Dana Creech, was using K&N filters and Powerlids and convinced him to make the switch. Once Danny started using K&N products he started winning races and championships. He told us he can't help but to feel that's not a coincidence, adding "I will always use K&N filters in my race machine and personal vehicles. K&N Powerlids and air filters allow us to have quicker pits stops, better filtration and a lifetime of reliability. The Powerlids increase hp, air flow and are very easy to change. Races like Vegas to Reno or the Baja 1000 require changing air filters about every 200 miles. With the K&N Powerlid our team can run the entire race without having to change any saving us time and keeping our engine dust free." If Danny can rely on K&N's performance and longevity in dessert conditions then the rest of us can rely on K&N during our daily commutes.

Danny is looking forward to 2011, more wins, additional championships and K&N filters and Powerlids to help him get there!

Find K&N products for your vehicle using the K&N application search then use the K&N dealer search to find a K&N dealer in your part of the world.

K&N Employee Takes Trophy At 2011 Grand National Roadster Show For His Custom Sportster Bobber

14 Feb 2011

1999 Harley-Davidson XL1200C Sportster converted to Bobber

Typically when one thinks of art, and artists, visions of paintbrushes and canvas come to mind. However, according to Webster's II new college dictionary, first edition, 2004 the word art can be defined as "a conscious arrangement or production of sounds, colors, forms, movements, or other elements in a way that affects the aesthetic sense." In that respect, the show winning motorcycle of Todd White and Matt Dawson most certainly qualifies as a work of art.

Harley-Davidson Aircleaner

The general public has been familiarized with the custom chopper motorcycle by popular television shows and famous bike builders. The word bobber may still be new to many folks out there. A bobber usually retains stock frame geometry, unlike a chopper, and takes a stripped down, minimalist approach to styling. Bobbers can trace their roots to the late 1940s and can be considered some of the earliest custom motorcycles.

K&N employee Todd White and his good friend Matt Dawson spent six months transforming a stock 1999 Harley-Davidson XL1200C Sportster into a one of a kind bobber.

Harley-Davidson Oil Filter

The build was described as a melding of Matt's vision and skills, with Todd's hard work and money. The duo was influenced by post World War II era motorcycles, and attempted to create a nostalgic looking motorcycle out of a modern machine.

As most motorcycles at the end of World War II lacked rear suspension, commonly referred to as a hard tail, the rear portion of the frame was removed and a new hard tail section welded into place. This also stretched the motorcycle by four inches. Modern telescopic forks were not usually found on motorcycles in the 1940s, so the front suspension was replaced with a Springer type front suspension. But perhaps it's the small details that really set this motorcycle apart.

Todd White on his Harley-Davidson XL1200C Bobber

The cooling fins were rounded for a vintage look and custom rocker boxes, similar to those made famous by Panhead motorcycles, were installed. Cloth braided hoses were used instead of rubber or stainless steel. Leather ties replaced plastics ones and the motorcycle's electronic components were relocated to be less conspicuous.

Proper filtration is critical even for custom motorcycles. Installed on this motorcycle is one of K&N's custom air filter kits, and K&N Wrench-Off Oil Filter® part number KN-170. "The K&N oil filter looks really good on the bike, and the nut makes it easy to get on and off" said Todd White, who is a the Product Manager for Existing Tooling at K&N.

This 1999 Sportster bobber is Todd's first custom bike and many people are surprised to hear that he actually rides it. "I ride it hard" said Todd, "when I get home from work on a nice afternoon, I'll take it out for a ride." Next on his build list is a custom Triumph motorcycle and an old Ford pickup.

K&N offers air filters, and air filter kits for a wide variety of applications whether it's for a custom vehicle or stock from the factory. Find K&N products for your vehicle using the K&N application search then use the K&N dealer search to find a K&N dealer in your part of the world.

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