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Jeffola

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Rather than your roadrunner, coyote manhole covers (I liked that), I just laid a strip of vinyl over the entire surface under the rails. Then the clips penetrate and you can use butyl or silicone to seal them. You went much further than I did, I also did a seal kit for the tailgate but I still get water intrusion. We're all going crazy fixing fords F-up.

Ford Ranger Weatherproof Bed Project -  DIY Writeup IMG_2966
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Yep your pictures and info is what got me started. :beer:
 

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Did you make the tailgate seal or was that a kit you bought?
 
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Did you make the tailgate seal or was that a kit you bought?
Not sure who you're asking but I've driven hours in the rain and an hour in the heaviest rain imaginable- not one single drop under the tonneau. So my efforts worked, and that inexpensive tonneau doesn't leak.
 

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Oh yeah we plan to use totes. But road dust is also an issue so this should stop most of that.

We had a day of thunderstorms and heavy rain, so I went for drive on the highway. Only had 3 small drips, one is at the right front corner where the tonneau sits on the joint where the side rail meets the front rail seal (my fault,) the other two were both on top of the rails where the tonneau seal joint coincides with grooves molded in the rail. That was it! And I can probably address those easily.
The tailgate area was totally dry.

1000014741.webp
Sorry I guess it did not quote like I asked. In this pic the tailgate seat was that diy or was it a kit. I use the diamondback bed cover and love it but my main source of dust and water are from tailgate.
 

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Sorry I guess it did not quote like I asked. In this pic the tailgate seat was that diy or was it a kit. I use the diamondback bed cover and love it but my main source of dust and water are from tailgate.
Not a kit, I did it from scratch. Seals well. Details earlier in this thread.
 

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Having done similar on multiple trucks, I’d never do it again, ESPECIALLY butyl and HVAC tape.

Forbid ever having to remove that crap again.

Just a heads up the juice is so not worth the squeeze.
 
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Having done similar on multiple trucks, I’d never do it again, ESPECIALLY butyl and HVAC tape.

Forbid ever having to remove that crap again.

Just a heads up the juice is so not worth the squeeze.
I'd never use duct tape. The butyl I'm familiar with from decades as an RV Tech. Remove it in winter. Remove any residue with auto painter's prep solvent. Plus I applied it to a waxed surface...
 

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Some good info in here! Might have to tackle something this at a later date, but gave me some ideas for some stuff I could do now to help minimize water entry.
 
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During our summer trip we went through some horrendous thunderstorms and a tropical depression on the Gulf Coast. Never had more than a few drops get in.
 

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I was about to do this, only the holes on the top you mean? Or you remove the trim to close the whole on the metal sheets as well?

Where that 10% remaining comes from in your opinion?
10% was a guesstimate. it's probably less. Heavey rain intrusion is almost nil, I get more from going through a car wash. I suspect that even though I have the stake pocket covers sealed well, a tiny amount makes it past the rail covers. Also, the tail gate seal isn't perfect, but it is more than adequate.
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