Truck Topper Brace

[eaneumann]

Hello all. I'm looking to build a brace for my truck topper. I have a 2012 Toyota Tundra Crewmax with a Prinsu rack on my topper. I'm looking to build a cage on the inside of the topper to support the weight of our tent/people/dogs/gear, about 800lbs stationary. While moving, the rack doesn't need to support that much weight, 250lbs max.

I've been trying to decide on using steel or aluminum. I do auto body for a living and have access to all of the tools I would need, I just don't have any experience with engineering such a project. I would like to use aluminum for weight savings unless there's a good reason not to. Cost isn't really an issue, I want to keep it around $500 for materials. Labor is free!

I'm currently using two bed crossbars from Relentless Fabrication to mount my tent to the bed. I'll be using the same mounting method for my brace/topper, it will eliminate the need for clamps. For the shape, I'm looking for something very basic, along the lines of an All Pro bed rack, but maybe just two crossbars with small feet like the Relentless Fabrication. Maybe 3 crossbars would be better? I was thinking 1" tube, but am looking for suggestions. I'm also thinking 1/4 for all of the brackets, maybe overkill?

Relentless Fabrication bed crossbars http://www.relentlessfabrication.com...ross-bars-pair

All Pro Pack Rack http://allprooffroad.com/truck-parts...-07-16-tundra/

The bed of the truck

 

[matt_i]

The links are both 404 for me (page not found). Maybe I'm doing something wrong...

Also, I would use steel for the framework as I am guessing you could get it nicely painted when done. Easier welding, more forgiving when bending. You will need some way to bend the tubes (could even be an EMT conduit bender if the wall thickness is similar)

 

[eaneumann]

Sorry about the broken links, not sure what happened.

http://www.relentlessfabrication.com/products/07-tundra-bed-cargo-cross-bars-pair

http://allprooffroad.com/shop/07-crewmax-weld-together-packrack/

I do have a tube bender and welding either material is no problem!


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[ilovevocs]

I would fab something like your second link then use these to connect them through the cap to the rack on top the cap. I see no need for the cap to actually support any weight in this application.

https://m.summitracing.com/parts/tg..._-trail-gear&gclid=CPHumbiLgdICFZeEswod_DUJ9g

Waterproofing is going to be the biggest issue. May have to fab some sort deck flange to seal to the cap with butyl sealant or tape.


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[kbs2244]

There is a huge amount of flex going on back there.
Allow for it.

 

[eaneumann]

Flex from the bed to Topper should be very minimal. The rack attaches to the topper with 6 feet, 12 bolts total. I will make similar feet on the inside that are welded to the brace. I'm more looking for suggestions on what material and thickness will be best for my application.

The rack.



The feet.



The bolts.



Thanks everyone!

 

[hedgehog]

those lights look super handy , did they come with the topper? switch on the topper door?

 

[kbs2244]

If what you want is inside bracing for more load capacity then keep it simple.
You already have roof through bolts.
So a brace arch from the bed rail, up to the through bolts, across to the other side and then down to the opposite rail will give you increased weight carrying ability.
Tie the 2 arches together with a two peice "X" to stiffen it up.

Bending the uprights to match the arc of the topper will make it a much more difficult fab.
I would just go with straight tubes and see if you can live with it.
If not it can be your first upgrade.

I would guess steel to be easier to work with and cheaper.
You are not talking about enough material to make weight a factor.