Custom stake pocket covers - DIY

[wannagofast]

I ended up trying a pressure washer on the rails and cover and had some tiny leaks. I narrowed it down to the little perpendicular gaps where the cover sits on the rails. Ford what the heck is this design, guys?

Anyway, I took it all off (that sucked) and added some very thin EPDM strips in those gaps. I cut the sides of the EPDM foam at an angle so the sides get larger the higher up, which is the opposite trapezoid shape of the these grooves in the rail caps. When it compresses it fills the void entirely.

I made sure to keep them just a bit shorter than where the weather seal for the cover contacts the rail so you can't see them but they fill the gap. While it was all off I also added a tiny bit more Butyl rope in the top corner seams near the cab.

I think we are good now

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[wannagofast]

Decided to try to fill the awkward gaps that are left. Used EVA foam with a hot knife (and ventilator!) Started by making stencils first, good EVA is not cheap! The very large gap towards the bulkhead is not 100% a tight fit. It's a very strange shape. It's about a 90-95% fit, which seemed like a win without spending a whole day trying to get it perfect.

 

[FairOaksRaptor]

Ah interesting setup! Sure thing, it's attached here.

I have a roll-up tonneau cover and came across a good deal for some Yakima racks. I will need to create a 7.5”-8” lift so the racks clear my tonneau cover when rolled up.
I’ll give my fabricator your file and then we’ll stretch it for the 8” we need . Once done I’ll share the photos and steps.

Thanks again for sharing.

 

[wannagofast]

Of course good luck!

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