Shorten a fiberglass truck cap

Discussion in 'Fiberglass and Composite Boat Building' started by imagineer, Jul 29, 2008.

  1. imagineer
    Joined: Jul 2008
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    Location: Ohio

    imagineer New Member

    I figure this is just about the best resource for info on fiberglass repair so...

    (BTW, file this one in the, "You're going to do WHAT!?!?" category)

    I recently picked up a '93 Dodge Dakota for a project. I have an opportunity to pick up a near perfect $700 fiberglass cap for it for $30.
    The problem, my truck has the 6'-6" bed and the cap is for an 8' bed.

    I've done fiberglass repair before on a small sailboat. It's not fun, but I think I know what to expect.

    I'm thinking I can take out the side windows from the cap and then cut the cap in half crossways, taking out 18" or so from the middle. Then it should just be a matter of bringing the halves together, reinforce and weld the base rails, glass it together from the inside, fill & spray gel coat the outside then modify the windows to fit the shorter opening. Simple, right?


    Can anyone out there enlighten me as to what my naive ambition is overlooking?
     
  2. fiberglass jack
    Joined: Dec 2005
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    fiberglass jack Senior Member

    sounds like you already know what to do
     
  3. losttool
    Joined: Jul 2008
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    Location: Lexington

    losttool Junior Member

    Cuttin up

    Go for it!
     
  4. Pylasteki
    Joined: Apr 2008
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    Location: North Carolina

    Pylasteki Junior Member

    Build a frame, or make your cut with it installed on the truck... Otherwise you've got a possibility of building in a twist.

    Good luck.
     
  5. the1much
    Joined: Jul 2007
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    Location: maine

    the1much hippie dreams

    put a 2x4 across the cap,, on the inside, against the "roof" and at the bottom where your bed connects,,,do this for both cuts,,,,before any cutting,,,,it'll keep it from twisting, or flaring out.
     
  6. fiberglass jack
    Joined: Dec 2005
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    Location: toronto

    fiberglass jack Senior Member

    if i was you i put a add on craigslist and try to do a swap, when you cut and rejoin the box make sure you dont over do the glass work, as down the road the repair will start to stand out, also the amount of work involved all the body work and paint, and if not done right it will always look like a homemade job, but if you have time on your hands go for it, Jimmys right about bracing the box first important to keep her square
     
  7. tinhorn
    Joined: Jan 2008
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    Location: Massachusetts South Shore.

    tinhorn Senior Member

    Most craigslist people I've dealt with are freaks and weirdos. There's a reason they can't use eBay.

    I'd make the cut at the very end, not in the middle. A patch at the corner (like next to the cab) won't be as obvious as one in the middle of a large, flat panel.
     
  8. fiberglass jack
    Joined: Dec 2005
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    Location: toronto

    fiberglass jack Senior Member

    guess Iam a weirdo,
     

  9. the1much
    Joined: Jul 2007
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    Location: maine

    the1much hippie dreams

    i knew that was you i saw on craiglistpersonals,,,hahaha ;)
    something bout trading ya cooking utensils fer sexy boat pics,,,hehehe :D:p:D
     
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