Opinions on repairing cracks in truck canopy/topper

I have some cracks in my canopy and am looking for input on the best way to fix them. The canopy is an eight foot Leer on my first gen RCLB (rare as heck) Tundra, so replacement isn't probable or really of interest.

The canopy is probably about 20 years old just like the truck. I'm planning to add roof rails and rack that at times would carry a Thule. Let's call it 100 lbs of possible weight up there.

With that in mind, I want to make sure this canopy won't fail. Also, it doesn't need to be particularly pretty.

Do you all think this could be adequately fixed with sanding down, fiberglass tape, bondo, sand, paint?

Here are photos of the damage. Drivers front is the worst with cracks around the window, clearly being cracked through, with a huge hairline crack running down toward the rail. The passenger front has hairlines at the corner, as does the passenger rear.

 

It can probably be fixed as long as it's not eaten up with mold/mildew- look on youtube at some of the boat repair videos and they'll show you how to clean out the cracked area and reinforce it with new material and epoxy/gelcoat.

This guy has some good repair videos, I'm sure there are others out there.
https://www.youtube.com/@boatworkstoday/videos

 

This is probably your best chance at saving it. Those are some serious cracks there. You really can't use anything like bondo. That would just fill in the cracks and not offer much support. Fiberglass and resin looks like the way to go for sure.

 

Watch how he fixes this one for some ideas on what it's going to take. He uses a laminating resin and pieces of fiberglass strand to build up and reinforce them goes over it with another resin mix to cure. To do it properly with structural integrity is not as simple as buying the Bondo fiberglass kit at your local Walmart. That said, it's a shell, not a boat and if you're not going to load it up and subject it to the stresses a boat undergoes you can get away with a lot more (less work) if you're just wanting something to keep your cargo dry for a couple of years.

 

Very salvageable. That looks like a very low end Composite repair. Agree with all the points above. You’re looking at layered sheets of fiber and epoxy for the structural fix. This project would be a great learning opportunity. Biggest risk is it looks like garbage on the inside. Nothing some sanding and carpeting wouldn’t be able to fix though

 

Free tip- make sure you work in a well ventilated area and allow yourself a small exposure before you start messing with larger quantities. Some people have really bad reactions to the chemicals just being near it (MEK for example is really nasty); wear gloves and a properly rated respirator, not just a dust mask, when working with the chemicals.

 

Thanks for the input all. Picked up a West Systems fiberglass kit and planning to get started in the near future once temps warm up a little bit (entering a cold spell in Central Oregon). Will post an update down the road.