sushidog wrote:Right now, I'm taking a 10-12 mpg hit when pulling my little Aliner at highway speeds!
With a 22 mpg city/31 mpg hwy EPA sticker on the automatic transmission, any drop is noticeable. The Cobalt has a tow capacity of 1000 lbs according to the Chevrolet website. It looks like your Aliner is the Classic model, which has a weight of 1430 lbs according to this website: http://www.aliner.com/design/products_detail_aliner.php?prodid=3
I'm sure the tow limit is relatively conservative, but above the tow rating has got to be straining the engine. I do wonder how much of your drop in mileage is due to that. To help with the aerodynamics, you could build a trapezoidal shaped wedge on the forward end of the trailer basically following the triangular tongue bar. Thin plexiglass over pvc should work well and keep the weight down. Make sure to close off the bottom too, so you don't have air swirling up from below. You'll see some improvement, but not going to get much of that 10 mpg back.
The Toyota Rav4 with 3.5L V6 and automatic transmission 2wd is listed at 19/27 mpg and has a tow rating up to 3500 lbs.