1st Gen Topper Rebuild and Internal Frame

Yep, I’m considering on selling the house and going full time in the truck while I’m not on the ship. Gonna have to start coming up with a plan for building out my camper shell... Looks great!

 

Finally did the rear lower brackets. I plan on using the hole in these to tie to the bed stiffeners with some turnbuckles. I just have to figure out the right size.

these thread into the tapped ends of the side rail. I also 3D printed a spacer which you can’t see.

 

Also finished wiring in the power windoor locks. I still have to figure out the rear hatch lock, but I can now unlock the side windows and tailgate with my fob. There are way easier ways to do this, but I didn’t want to have to unlock them after each time I closed them. I also wanted to make it seem as if the handles are locked so someone wouldn’t just turn them and release the tension on the latches.

https://youtu.be/2n4xSMi9DrM

 

How did you install that rail on the first gen bed?

 

Are you talking about the l-track? It’s just bolted through the lip on the inside of the bed.

 

Finally connected the bed stiffeners to the internal topper frame. I am hoping that this will keep the topper sides from spreading apart at the tailgate. I had to piece together some custom turnbuckles since most complete sets were too long.

 

Dig it! Just stopping in to say thanks for posting this. I started dreaming up something for my 2nd gen like what you did and glad to see a precedent.
Is this pretty much all 1"x2" extrusion? Looks like plenty of open space.

 

Yes everything is 1"x2" except for the front lower rail. This was because there was already a 1"x1" piece of aluminum imbedded in the topper.
I decided on 1"x2" instead of 1.5" because I could fit it inside of the side rails very easily. 1.5" would be slightly too wide.

 

I just put Front Runner tracks on my Leer 100XR and plan to move my RTT on the shell.

I looked at the Milford LoadMax and agree they take up too much useable space of an already small truck bed.

I'd LOVE to do something like this for my 3rd Gen. Your thread is the only one I can find of someone actually reinforcing their camper shell.

 

It would be much easier to just cut and weld steel or aluminum pieces. I had to make it hard on my self with aluminum extrusions.

 

I'm not much of an aluminum welder (or a welder at all for that matter), but I've been contemplating how I'd do an internally supported frame just to take some of the weight off the shell and down into the bed sides. I've installed Total Chaos bed stiffeners which should help with the added load on the bed walls if I ever do.

Your setup is MUCH cleaner than what I could put together. The aluminum extrusion looks great.

 

I don't think the extrusions are all that difficult. I can bend and weld but sometimes it's nice to work with something that makes you be limited in the design options.
Mine got started but I wrecked my truck so it's currently still in mock up phase until insurance and body shop can agree on fix or total the truck. I'm actually further along than these photos, the top frame is done just need it on the truck to set the angle cuts right for the vertical extrusions down to the bed sides.

 

How did you seal the screw holes to prevent leaks, rust, etc.?

 

Comprehensive write up on a creative build. Thanks for posting!

 

Silicone and rubber washers come with the track kit from Yakima. Pretty typical installation for these tracks. A little silicone around the hole before setting the track down and a plastic or neoprene washer under the screw head works a treat.
I do finally have the upper frame mounted in mine…been awhile since I’ve had time to work on it but I’ll post some photos soon.

 

Nice. Appreciate the response. Looking forward to the pictures.

 

I've been noticing mine starting to spread at those bottom edges as well. I have the stiffeners on the bed, but there's really no good way to attach to the topper without adding a frame or something like you have.