I’ve finally gotten a fiberglass cap with contractor windows for my Chevy full size and I plan to build shelves at the front of the bed and part way along the sides to hold tools. I haven’t paid attention to the others I’ve seen and I’m looking for advice on anchoring. I hate to think of drilling holes into my new truck, so I’d like to keep screws to a minimum. I’m also planning a sliding platform attached to the bottom of the shelves that I can load my portable table-saw (bosch) onto and slide forward for travel. Any tips will be appreciated.
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What did you use to anchor the cap to the bed? My truck has aluminum clamps to clamp the cap to the bed (4). When I put the shelf across the front I rested it on the cap sides and slid 2 of the clamps up tight against it. I put a lip across the front (2x4) to keep stuff from sliding off and to help stiffen the shelf. Your cap dealer should be familiar with these clamps. I looked at mine to see if there were any markings or brand, but no go. I'm still trying to come up with a good idea for the sides, so I will stay tuned. Good luck.
Dana
If you want to go to something in a metal shelf, Adrian Steel makes a variety of units with shelves and bins and drawers. I don't know about the attachment methods here but the units themselves are fairly sturdy. And how about an Extend-O-Bed (or similar) for the saw? This may go far in saving the knees by not crawling around in the bed so much. Just a thought...
Steve
I've built three pickup truck boxes - all three side by side drawer units kinda like the ones previously described. They all just fit right in there and really don't move around much. I used that UHMW plastic for glides....can't beat it. The really grooving one comes out in three equal pieces and fits into a rolling rack that doubles as a chop saw table ( the boss has it) I'm about to retrofit the one I have now with a sliding top (for my table saw, air pump, etc) I've made them all with 3/8" plywood, 3/4" plywood ends and 2 part glue and tape. You can to. Just imagine your dream set up and head to the shop. I got the time down to 15 hours and $100. If the first ones don't seem right, do it over! You deserve to be pleased with it!
I built shelves for my truck in 3 sections. The two side units are 3/4" ply uprights dadoed to accept the 3/4" ply shelf. The shelf is strengthened by a 1x4 glued and nailed to the front and back of the shelf. One shelf right over the wheel well and then one with just enough space between the shelf and top of the cap for items like nail boxes, levels, pipe clamps, etc. In the front I have a flat shelf, again 3/4" with 1x4 for rigidity that has 18" of clearance beneath it and it's 16" deep. Across the top I screwed 1x4's to cleats mounted on the top shelf of the side units, with just enough room to slide my brooms and shovels in on the top. That keeps the side units in place.
I built a 3/4-inch plywood raised deck in my truck box, resting on the top of the wheel wells, supported across the width of the truck by 1x2 yellow pine "joists", and supported at the front corners by little 2x2 posts. To keep the deck from sliding to the rear when driving uphill I put a little stop block between the deck edge and the clamp that holds the cap top to the pickup bed. The deck covers 2/3 of my truck box, leaving the back 1/3 full height for my buckets and compressor and a rolling trunk I use to house my tool belt and hand tools. Under the deck, in the "basement", I use two mortar tubs, the plastic kind that are about 8" deep. The tubs hold all my tools I want to keep out of sight such as nail guns, belt sanders, drills, etc. A rope pull on each tub makes it easy to retrieve the tub when I need it. The plastic tubs cost only a few dollars each, and slide very easily on the floor of the truck. When I need too, I can take them out for mixing mortar or small batches of concrete. In the top of the truck cap, above the side window level, I have built in two small shelves for things like first aid kit, tie down straps, and a place to hang my 4-foot level, my broom, and the dustpan. Andy Lee
first truck cap I had I made two plywood trays which set on the bed where the cap was fastened to, and hung it with plumbers tape from the aluminum frame above, nothing fancy. Now I got the whole 9 yards, cap with buit-in side boxes, xtendo bed, the best part was discarding the tailgate and useing a large fold-up door, great place to huddle under when it rains.
Like Andy I built a deck about ¾ the length of the bed at the level of the bed rails. This deck is self-supporting with 2x4 legs. Since my topper only has a built in tool box on one side the opposite door opens to the deck where I can carry as many tools as I need and still have the entire bed floor for materials.