Camper Shell Build

I've been working on a camper shell for my 97 tacoma that I found on craigslist for $125.

The cap is a high rise A.R.E. model that fits my single cab perfectly, but doesn't have side windows.

I found another cheap cap (I think it was a Brahma?) on cl and pulled the side windows from that.

Currently in the middle of insulating the cap and lining with carpet. Been using 3m 90 Industrial Spray Glue, and aside from an issue with the first can that lead to a respray of most of the insulation, it's been pretty smooth sailing.

Once the cap is carpeted, I'll be cleaning the window frames and buttoning it all up.

 

The insulation is Reflectix, comes in rolls from the hardware store. There's a noticeable difference in temp with it in place, and it's pretty easy to work with. Flexible and cuts well with a razor blade. I've got new seals on order and will be building a platform for camping once the topper's ready to go.

 

Nice grab!.. Thats the A.R.E. TW series if I'm not mistaken. I've wanted one in black for the longest time. Not sure if they still make them for the 1st gens but they're pretty pricey brand new. I've researched a bit on Truck camping and there some pretty sweet set ups out there. Looking forward to seeing the finished product.

 

Cool, thanks for the info! I drove with it on the truck for a few days and it looks massive with stock suspension haha. Hopefully my tax refund will help take care of that though!

 

Insulation and carpeting is done! Managed to get full coverage from a single 8x10 outdoor carpet from home depot. Had to get a bit creative filling some gaps and stuff, but it looks pretty nice overall. Waiting on a few more feet of window seal, but should have it on the truck by next weekend.

I had originally planned on having it painted to match my truck, but Maaco's pricing for toppers started at $550... no thanks. I'm gonna color match my grille and use it as a test run for automotivetouchup.com's paint.

 

Yep, It'll definitely be cheaper to do it yourself. Not sure what a paint spray gun at Harbor freight would cost but if you have a garage and could rent/buy some industrial heat lamps you could save you some coin.

 

Unfortunately I'll be moving at the end of the month and will no longer have a garage. I do have access to a spray gun through work though...

 

Looks pretty good. Wish i could find a catch on a shell like that.

 

Thanks! Yeah, I'd been looking for a few months. Found multiple single cab shells on trucks for sale but nobody would sell just the cap. Eventually drove an hour and a half out for this one.

 

Got the carpeting done, cab facing window and lift gate sealed and installed, side windows are just mounted to see what it'll look like (I'm waiting on the seals, the shipment was supposedly 3 day shipping, I ordered it last Saturday... lol)


Some of the seams are visible, mostly at the front corners, but overall I'm happy with it.

This project was a great excuse to buy a ryobi impact driver/drill set, I love it!

Sorry for all the upside down images, I keep forgetting to rotate prior to uploading and I'm too lazy to change them out.

 

@lukester78 Great looking shell! I just got a similar ARE shell off of CL. (pic below). Im starting the same process of insulating my shell as well. I wanted to know if you used the same spray adhesive for attaching the carpet to the reflectix and is that the only thing you used? Wondering if I need to use a staple gun to keep the weight of the carpet up. Thanks for any info!

 

I used 3m super 90 for reflectix to fiberglass and for carpet to reflectix. The carpet I used is super lightweight, it was just a 8x10 indoor/outdoor carpet. So far I haven't had any issues, but I did have a faulty can and had to respray initially. We've had quite the variety of weather here in CO since I finished and I don't think anything's caused a problem so far.

 

Do you spray adhesive on the ceiling, then apply the insulation, then spray more adhesive, then apply the carpet/upholstery? Did you install those windows yourself?

 

Awesome work, nicely done

 

Nice Job. You've put in some "sweat equity" and got yourself a nice top.

 

Spray both surfaces that'll be glued together, let the glue sit for a few minutes, then press together.

I did install the windows, I pulled them out of another topper and used a cardboard template to make a rough cut using a cheap jigsaw.

 

That is the exact boat-top style that I am looking for...

 

Here's what it looks like on the truck


Really pleased with how the windows line up with the cab door window.

Nearly a year since I insulated and lined the cap, it's holding up well. I think I'll be putting in a 3rd brake light this winter. Need to lift the cap and seal the front edge of the bed better and seal the tailgate at some point. Maybe replace the hatch seal on the topper as well.