I will try to get it mounted on the truck in the morning. I will update for now what has been done.
The bright Stainless handles had to be toned down. I don't really have any chrome on the truck. Started out with self etching primer and roughing up the surface.
After applying about 6 coats of LOW gloss black I think its good.
Here is a before and after
Next I removed the door plunger type stoppers that keep the door open. I am installing gas shocks on each door to open it and keep it open when it's windy out. So the holes needed to be filled in on both doors, 8 holes in all.
Here is a shot before it was painted. I also have the rack mount mocked up and sitting in place here.
What I came up with for the rack is kind of different than what most of the aluminum caps have. Most caps come with vertical bars that come down onto the side of the body. Looks not so great but holds the weight good. So I started trying to find a way to hold the weight without big bars coming down the sides. What I was first looked at doing was running a support inside the cap from the front to the back on both sides to hold the racks weight. But after thinking it over I did not like all the space this would take up inside when it could go on top of the cap. Plus I would loose space were I could be insulating the cap.
So on top it went. This bar is 1/8" wall 1”x3”x almost 7 feet long. One on each side and super strong when it all gets bolted together. Best part is nothing hanger down on the sides of the cap. The outside rack bars will bolt directly into 3/16" thick plates welded to the inside frame on each end of the cap. Plus the rack bars run over a frame piece just under the tool boxes, adding to the strength.
This rack mount exoskeleton works out great for my next idea I was trying to get worked out. A rear awning and storage for the awning poles. The 1”x3” bars will house the pull out awning poles. At first I wanted to have the awning full together at all times and slide between the rack mount but it worked out to be to narrow. So next best thing is just sliding the awning material on after the poles are pulled out. These awning poles will only add the strength of the rack mount in the stored position.
Here a mock up of the poles sliding out of the rack mount.
And one more shot with some wood poles used to test the lenght they will pull out. I am thinking I will have a covered area about 3 feet by 6 feet. Don't let the wood sagging fool you....
OK your almost caught up....It's now a beautiful Toreador red with all black trim!!! I need to put the cap together in the morning and get it mounted up. I need to get all the doors back on and insulated. I am also working on a better way to mount the cap. Most places just drill holes and bolt it down. I am going to try to clamp it down; less holes drilled the better IMO….
Louie
Edit:The big hold up on getting this cap done is
to many projects!! I am in the middle of Bushwacker cut out flares, 37 BFG Baja's with double beadlock wheels and a new Warn winch bumper.
