Heavy Taco - Canopy Reinforcement with Internal Frame [ENDOCAGE]

For this one I prefer "Endoskeleton." Maybe even "Endocage."

Either way, this was an epic project done by my dad and I. SO MUCH FUN. SO MANY STEPS... so I'll try to keep this as concise as I can.

The problem: Increasing the load capacity of a truck cap / truck camper / truck shell (whatever you want to call it) while keeping aesthetics in mind, without having a lot of junk sticking over the bed rails.

The solution: AN EXO CAGE! YES! well... That was my original design, but was contingent on finishing my new rear bumper for the second mounting point. First mounting point being my welded-on rock sliders.

With solution A out, solution B was to investigate an internal frame to support a fully loaded roof basket.

Solution B: The way we worked it out was to essentially make an independent support structure that is permanently installed inside the cap. The loaded basket is supported by the frame inside, essentially removing the stress from the fiberglass almost entirely. The key was a PERFECT fit. This took a lot of test fitting and tweaking, but it was well worth spending the time to make it right so it can function as designed.

We started this on a Friday after work, and each put in around 35 hours over the next couple of days doing individual tasks to make this happen (approx. 70 hours worth of work total)

First task: RESTORATION. Removing window trim, replacing screens, repainting window trim, bolts etc. and painting the inside of the cap. While I got busy making things look fresh, my dad (@ajthefabricator) started making a tool and jig for his press to start bending the 3/4" square stock.






Fresh screens. NO MORE HOLES!


Prepped and painted. So fresh. So nice.


Fresh window trim... of course.


And fresh hardware. Of course.


Upon reassembly, I added some little D rings to hang curtains.


AJ's tool and jig to bend the square stock (slightly modified Harbor Freight press)


The raw material. Notice a little sag in that flat bar over the span of 10 feet. That thickness was intentional to more easily contour to slight inconsistencies in the bed rail / truck cap (I'm talking to you, LEER!)


The tool and jig in action. Working perfectly as AJ intended. TOO COOL!


Took A LOT of massaging to get these complex curves to drop in without forcing them. DON'T FORCE IT! Just take the time.


The main curves are fit. Now to work out the next angle...




This bend follows the window trim. Notice the half lap cut at the bottom. More to come on that shortly.


Stick clamps rule. Notice that perfect fit.


The bottom half of the puzzle. Gussets of course.

EXPLANATION BREAK:
So, with the two upper arches 'clamped' in their exact location, the bottom rail could now be placed on the bed rails inside the cap, and clamped to the upper arches.

This is a PERMANENT install. The half lap seam is to get as much weld for the strongest seam possible. This whole thing is about strength. No need to blow it all with a butt seam.

Once both pieces are mated inside the cap, they are then welded together, to live inside forever and always.


The Wizard and his wand. Making the upper arches and lower base one. This is officially an Endocage.


Hit the seam with some matching paint. I didn't grind the welds intentionally so I will always have the reminder of how this thing came together. It's just so damn cool.

SO... the basket. Before we started drilling into my precious fiberglass, I had some work to do.


Wrapping the exterior in gloss black vinyl was my solution for sealing some funkiness in the gel coat that was allowing moisture to collect on the ceiling whenever it rained for a couple days in a row. Just a little insurance for the big trip in two weeks.


Cutting down some pipe for the basket clamps.


Drilled, filed and painted basket clamps.


Moderately modified cable clamps for mounting my waterproof box to the 1/2" dia. basket tubing.


You see where I'm going here...


Custom inner clamps.. Of course. The point of this was to keep the mounting bolts on the inside of my lockable box. Oh yeah, "custom" paracord lid stops as well. lol.


Waterproof box for tools and spare parts (just enough inner height for a 1st gen CV axle still in the box)


Taking a little mind to keep my waterproof box waterproof, I thought it would be slick to just thread the plastic to get an even tighter seal. (There is still a bolt head and large washer underneath.)


Topped off with black SikaFlex, fender washer, and nylock to keep 'er tight.


Making the knobs I got at the hardware store slip into these holes to keep things registered.


Left this outside overnight in a huge thunderstorm. Not a drop of water inside. Hell yeah.


Drilled up. Ready to drop the basket on.


Clampy Clamps working awesome! The rubber foot is a rubber piece of plumbing that I filled with a series of nested hose (think rigid radiator hose) It is not quite as dense as a hockey puck, but it is pretty dang hard. A dab of black silicone around the bolt and we are in business.


Canoe blocks...


Cut into little tiny feet.


Jammed under the "seams" in the Thule basket as additional support for any points that could potentially sag if a Grizzly decides to party on my roof.

Now that the cap is a lot heavier, it's time for the two of us to break our backs to get it back on the truck. A few F bombs later, it was finally lined up and clamped down.

I barely could enjoy the moment because I was just glad to be done after all the hours spent over the last 3 days.

BUT this morning I looked out the window and was SOOOO PUMPED.

This project absolutely ruled.





"If you put your mind to it, you can accomplish anything." - George McFly

 

Fucking legit

 

Looks great. I’ve got a similar cap that has sagged enough to puddle water in it. (Stored upside down in someone’s yard for years!) I might copy your ideas to brace it from the inside. Would like to see some more pics of the press jig for the bends. (Width and radius of the upper die and radius and spacing of lower die rounds. )

 

Awesome

 

Hell yes! Next time I am up there I will get some dims and photos to post in this thread.

 

Nice project and beautiful truck!

I second what Kwik said.

 

that only applies if you have the skills to accomplish a job like this. Me, I don't posses those skills. but you sir did a dam fine job. Looks good.

 

Mornin' guys. Just wanted to bump this thread since I just posted this cap up for sale! https://www.tacomaworld.com/threads/for-sale-1st-gen-reinforced-camper-top-w-basket-6ft-bed.807518/


Someone buy it before I regret this decision and change my mind!!!