Skinning Ladder Racks, Possible?

[Dale]

Considering: Skinning steel ladder racks with 0.023 Aluminum around four sides, fabricate solid barn doors and light weight steel on top for a strong deck. Would adhesive hold or should I add a thin piece of L to rivet to?
I like the A.R.E. DCU and Callen Campers but they are pricey even for the used/abused ones I've looked at. Truck (Ram 2500) used to haul ladders, lumber and extended weekend camping. Thought some of you with experience in this area could guide me.

 

[FlatlinesUp]

so you want to put a solid (thin) wall around both sides and the front and two solid (thin) small doors on the back? (or am I misunderstanding?)

Why? if you don't mind me asking? it will limit your ability to carry anything longer than the rack (ie extension ladder etc) and it will catch more wind/water

I got a good deal on a KargoMaster from craigslist and added some square tube and expanded metal and it's plenty strong enough to work/walk/store on top of (1700lbs rated stock), the second set of bars gives me plenty of place to tie off to etc

 

[Capt Sport]

FlatlinesUP,

I think what he's trying to accomplish is enclose the lower portion of the rack (the uprights) thus making an enclosed camper shell of sorts.

Dale,

I don't know if I'd trust adhesive, even though they makes some really strong adhesive for aluminum bonding I think I would still attach the aluminum sheet with rivets or thru bolted.

Just curious have you thought of how you'd seal the created enclosure? Assuming of course I've got your idea correct I think it' be hard to seal. Do you plan on carrying anything on top of the rack?

Here's a thought I had after I bought my camper shell. I'm really into boats and a lot of the build yourself boats use a technique called stitch-n-glue. (there's lots of info on the net) I've thought of using this method to build a shell out of thin sheets of ply molded over a wood frame and "stitched" and taped together. Once you get the first layer on you laminate additional layers over top to the desired thickness and remove the molding frame. From there you would cut the window openings etc and use windows from smashed camper shells or out of an old RV or camper. The exterior is fiber-glassed over and painted so would be tough. Also, you could build cabinets etc directly into the top since all you'd have to do is "tape" them in.

I think you could build one for way less than they want for a new one, btw mine cost me $1700 when I bought it. If I had to do it over again I would try the method I describe above.

Sorry for the long winded response, these adventure mod's get me all twitterpated and I get on a roll.

 

[Dale]

Capt Sport - I thought I would use some type of L for the corners, I have an old Haulmark box trailer with a rotted frame I was considering salvaging yhr corners from.
Flatlines- that is a really nice rig, I was thinging of a deck like yours with Aluminum around the sides.
I appreciate your suggestions.
Its still in the planning phase, I wanted to price out the materials to see if was worth my effort..

 

[762X39]

I have a ladder rack on my old work pickup and (a Kargomaster just like the one in a previous post) I don't think skinning one is a good idea. The cost of the materials will exceed the cost of a generic cap (especially used) and the racks tend to flex way more than you think.The skin will tear itself apart as the rack flexes and you will end up with a lot of work for no gain.Buy a cheap cap (even used) and modify the interior for your needs.Just my opinion but based on my observations with the ladder racks and caps on a fleet of trucks at work.

 

[FlatlinesUp]

Ok, I'm reading it right now (thanks to other folks lol)
Thanks for the kind words, it's still a work in progress.

762 makes some great observations and I've got to go with his thinking 100%... I got my rack from Craigslist for $250, and I've seen cheaper (quality and price) and I've seen truck shells of every size/make from $100 on up (even the newer nicer ones)