Today's project was to add bracing to the janky wrecked SmartCap, which involved making some brackets. I used 1/4" 7075 Aluminum I had on hand. The reason I had to do this was because the welds/folds broke when I was rear-ended, and the truck cap doesn't hold it shape very well- the bottom wants to splay outward, and I can't have that because the rear door doesn't close properly and doesn't, therefore, lock. So, I'm hoping this helps. I used ratchet straps to pull everything as close together as possible before drilling. I should add that, at some point I may replace this with a new truck cap, but figured if I could make my $5000 truck cap live again, it was worth a shot. Next steps are to replace the security screen, fix the brake light (need new wiring harness) and eventually add back all the lights and geegaws I had on the back and top. Once I get a job, I replace the suspension.
No, the braces aren't symmetric at this time...) So brace your OCD...
Bracket, inside driver's side. The bracket spans two broken welds/folds.
Bracket, inside passenger's side. This bracket only spans one broken weld/fold.
Driver's side exterior. I did drill one more hole at the bottom... and I'll fill the gap with buytl tape. The goo around the washers is also butyl tape. Debating whether to remove the excess...
Passenger side exterior. Also drilled another hole, so there's 4 on this side.
Overall, this did help the base stay together better, so far. The door closes better and the locks work on both sides now.
I also added more brackets to hold the truck cap to the truck bed... some of the ones I had were mangled so I just got another 4 and added them in. We'll see how this holds up!