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Old 10-24-2010, 11:27 AM   #20 (permalink)
EV test pilot
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Join Date: Jan 2008
Location: Oconomowoc, WI, USA
Posts: 4,435

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Wow, old thread....

I have too many unfinished projects.
Also, my first-born child just arrived this week. If it's not one thing, it's another...

Well, my great master plan right now is to build a cap out of fiberglass over foam. It will be sort of a big wedge.

Now here's the fun part I cam up with:
It will be hinged SIDEWAYS. I am imagining this as a piano hinge down the top of the driver's-side bed rail.

Hinging sideways eliminates any interference with the cab of the truck. It still allows me to easily get big things through the back of the truck, or over the side. I think hinging on the left side is best because that puts me on the sidewalk or away from traffic when parallel-parked in busy areas.
Side-hinging also gets rid of any problems of various joints that would have to be weather-proofed. (I want this to be rain-tight.)

My Dad has done some work the last while building wood canoes. They are made from cedar, and covered with a single layer of fiberglass (which just ends up being clear, showing off the wood.) He has all the fiberglass material. I just need the time and space to work on the foam to build the cap.
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