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How to waterproof stock rail caps that look good?

Breakthrough

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Joined
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Ontario, Canada
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2025 Ford Ranger XLT
I got the 3-panel REV tonneau cover from Ford, and want to make it fully waterproof. The tonneau itself is pretty water tight, but the inserts in the rail caps still leak badly. This was already discussed in another thread, but the end results usually look similar to what I have now:

Ford Ranger How to waterproof stock rail caps that look good? IMG_20250505_192528a840


I used a flowing silicone sealant, which seems to work well enough, however it doesn't look that great aesthetically. It also didn't seem to level itself out well. I might give DOWSIL 7094 a try, in hopes it will correctly self-level as it cures. Most approaches involve tape, silicone, or removing the stock covers, and each has tradeoffs.

I want it to look better than how it does currently... One idea I have is to fill the gaps with silicone putty, followed up by a some very low viscosity black silicone. I made some progress with that as shown above, but even with the product I used, the viscosity is too high. It gets everywhere and is a pain to clean.

Does anyone know of a low-viscosity silicone that would be a good candidate for this? Or any other techniques to seal them, while still looking good?
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Last edited:

Moonlit

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Chris
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Pittsburgh PA
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2025 Ranger Lariat (Marsh Gray, Rear Locker and BAP)
I got the 3-panel REV tonneau cover from Ford, and want to make it fully waterproof. The tonneau itself is pretty water tight, but the inserts in the rail caps still leak badly. This was already discussed in another thread, but the end results usually look similar to what I have now:

IMG_20250505_192528a840.jpg


I used a flowing silicone sealant, which seems to work well enough, however it doesn't look that great aesthetically. It also didn't seem to level itself out well. I might give DOWSIL 7094 a try, in hopes it will correctly self-level as it cures. Most approaches involve tape, silicone, or removing the stock covers, and each has tradeoffs.

I want it to look better than how it does currently... One idea I have is to fill the gaps with silicone putty, followed up by a some very low viscosity black silicone. I made some progress with that as shown above, but even with the product I used, the viscosity is too high. It gets everywhere and is a pain to clean.

Does anyone know of a low-viscosity silicone that would be a good candidate for this? Or any other techniques to seal them, while still looking good?
A bit OCD on mine, but I did the same with silicone, then scored the silicone below the edge and cleaned the up rubbing with a rag.
 
 







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