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Bedrug arrived this weekend and I started sealing every little crack or hole I find with butyl tape. Thankfully I work for a company that just has rolls of the stuff laying around, because I went through 2 yards of the stuff and I've sealed maybe 70% of the bed.

Biggest concern is how I'm going to seal up these large gaps at the bulkhead of the bed.

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not if you lock them while the latches are open, then they cant be locked. i installed 2 slide latches, one in each corner at the bottom to lock the lift hatch on the back. i did the same for the side hatches for emergency exit purposes at night
Can you add a couple of photos?
 
you need it to keep the popup from collapsing in the wind or from weight on the roof
When I said remove it I meant replace it with something else to hold it from collapsing. Just like on the other end. I assume the one end has the "stick" to aid in pushing the top up. Once up then anything can be used to lock it in place, like the lock on the back end. I was thinking of a push stick that was not permanently attached, and then a lock like on the other end to keep it in place.
 
I see. If you make up a different lock and use heavier rated lift struts you don't really need the push bar. I put 4 heavier struts on because of gear on the roof and don't use the push bar to raise the front. It goes up pretty easily. I just use the push bar for locking the top up.
 
I see. If you make up a different lock and use heavier rated lift struts you don't really need the push bar. I put 4 heavier struts on because of gear on the roof and don't use the push bar to raise the front. It goes up pretty easily. I just use the push bar for locking the top up.
I did not think of upgrading the lift struts. That is a great idea! When I get done I'll take some pics and report how it is working. Thanks.
 
Thank you.
Researching this.
Looking at Aluminum tape and Sikaflex 221 so far. Further research may conclude silicone sealant.
For the Tacoma in your profile? If so, check out KBVoodoo’s replacement aluminum bedrail caps, if not already known to you. Would have loved those for my Tundra, but only for Tacomas. I’d have put them on my old Taco in a heartbeat if I was gonna put an Ovrlnd on it. You still seal under them, but it's a much more durable and complete solution.
 
For the Tacoma in your profile? If so, check out KBVoodoo’s replacement aluminum bedrail caps, if not already known to you. Would have loved those for my Tundra, but only for Tacomas. I’d have put them on my old Taco in a heartbeat if I was gonna put an Ovrlnd on it. You still seal under them, but it's a much more durable and complete solution.
Thank you I appreciate the tip.
I looked at them. I have no idea what benefit.
 
Thank you I appreciate the tip.
I looked at them. I have no idea what benefit.
Seal the bed rail under the caps and the aluminum caps give a stable platform that doesnt warp or flex under the camper weight. Not strictly necessary, of course.
 
Thanks. I appreciate it.
I will file this under the 'keep an eye on the platform'.
There is so much in this thread I filed away.

I had an ARE MX for many years with the only leak being the front window frame (inside perimeter) fixed with a little silicone.
This camper with sleeping occupants are probably double the weight of the MX.
 
I’m in the middle of placing an order for a Chubby to go on my 2024 GMC Sierra 2500 AT4 truck with a standard bed. Anyone in here have the rear flip up hatch instead of the Barn Doors? That’s the only thing I’m not 100% on. I’d get barn doors 100% if they opened all the way against the sides like they do on the regular campers but they only open to about a 90 degree to the camper. I mean honestly how often do you really stand on your tailgate for something. That’s the only reason I can see having the barn door in the first place but maybe I’m wrong. I still need to use my truck as a truck so if I’m hauling long pieces of lumber I have no way to attach the barn doors to the side as they would be sticking straight out the side. Also at camp with them open you’d be walking around them all the time.

Thoughts on the Barm doors on a Chubby vs. the flip up hatch.
 
Made a last second change to the build. We’re going chubby!
Did you get your Chubby yet? Did you go barn doors or flip up. That’s the only thing I can’t decide yet on my build. Wish the. Hubby doors opened all the way like,on the regular Ovrlnd camper. So right now I’m leaning towards the rear flip up hatch so I don’t have to walk around the doors when camping.
 

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