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.

 

Repair would be the same as dealing with fiberglass stress cracks on boats. It is doable, take your time and it can look quite good and heck, you may get many more years out of your topper.

These should help
https://www.epoxyworks.com/index.ph...at should be removed,coat of paint or gelcoat.

https://www.powerandmotoryacht.com/maintenance/how-repair-spider-cracks-fiberglass

https://www.youtube.com/watch?v=339W-ZNC1_0

 

Unless you get pretty lucky and get a solid repair, chances are good that it is going to continue to crack. Once you put the rack up there you will be adding much stress too. Wish you luck, but don't have high expectations. Once these things begin to go, they go relatively quickly.

 

Darn, that's a bummer to hear. Mostly because this size canopy is so hard to find. Looks like the only options for buying new would be custom or a commercial unit through ARE or Leer.

I'll put some time and money into keeping this one functional. If anyone out there sees an 8' FGT canopy for sale locally, let me know! Driving cross country in a few months.

 

Don’t listen to that guy. He is wrong. Properly repaired that can be as strong or stronger than it was day 1. Grind down the crack past the damage and fix it. Or take it to a boat repair place and have them fix it.

One thing to note is you will 100 percent want to reinforce the topper if you’re putting weight up on top of it. Again talk with a fiberglass boat shop. They deal with that kind of stuff all the time.

 

Not sure if you missed it or what, I stated "unless you get a solid repair". Anyway, yes boat shop would be a really good start.

 

There’s nothing lucky about it.

 

Guess you aren't aware of the condition of the workforce in current times.... many people just don't give a damn anymore. On top of that, many companies don't give a damn about their customers anymore either for a variety of reasons. Luck is a factor!

 

^ Thanks gents. None of the boat shops here in Central Oregon are interested in the work. It's been about 15 years since I worked with fiberglass, will dust off the chops and give it a go.

 

Well I’m sure you know the drill. Grind everything down to fresh good stuff. Feather it in. Read directions on all your epoxy.

 

What do you all make of the kits available?

The BoatworksToday video is about a decade old so product recs may be outdated. There are a number of kits available, such as the West Systems 105-K or the Bondo Repair Kit 00420.

Will the 'fiberglass cloth' offered in those kits work well for the rounded edges and strength needed for the canopy?

 

I have always used the Bondo branded kits and had success. The problem with the toppers is that once the material reaches its yield in an area, the whole area in usually compromised. So, I would be certain to get well beyond the immediate areas of the damage with my patchwork if I was doing the work. Just don't want new cracks forming right beside the newly repaired spot if you know what I mean.

 

As for the rack, if me, the canopy gets laid upside down and I would wood frame support beams across the top with posts down the sides to transfer the load to the bed rails. Then lay fiberglass over wood and tie it all together. Beware of creating yourself something that you can't handle though, weight is and will become more of a factor as you press ahead. Wear a mask when sanding too!

 

West systems epoxy is what I have always messed with. It’s good stuff.

Oh you should talk to that one guy. Let me see if I can find what his name was I bought some stuff off him. He had built his own carbon bedsides and some other stuff.

 

I've successfully repaired a few rooftop boxes by using fiberglass repair fabric on both the inside and outside of the surface. Granted, this is a little different situation, but I think reinforcing both sides of the sheet is key to success and preventing future cracks, as it turns the existing material more into a "core" of a sandwich construction, so it isnt as stressed, and is less likely to crack further.

 

I'm going to hold off adding anything to the roof. The risk:reward ratio isn't there for me. Going to do my best with a double-sided repair to the 'bad' crack using the West Systems kit. Once the canopy fails I'll be looking to get some friends together for a welding project or see if I can find a used lumber rack.

 

Was feeling good about my sanding work getting down to good glass until I started chasing cracks on the bottom edge. Took a look underneath and it's super rotted out!

 

Guess you might have to cut it up into pieces and throw it away. Did that with an old boat once, not exactly ideal, but it got gone!