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Old 11-02-2009, 08:59 PM
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DaveInDenver DaveInDenver is online now
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Join Date: Jun 2006
Location: Larimer County
Posts: 7,866

Seems like all you need is a rib that follows the contour of the inside of the shell that runs from bed rail to bed rail under each rack cross member. I'm seeing 3/4" tubing, a bender and welded plates on each end. Very much like a internal roll cage that fits snug under the shell. Tie the internal ribs to the topper ceiling and to the Yakima or Thule feet on the roof, with, I dunno, u-bolts or maybe tabs on the ribs. The fiberglass in a topper is pretty strong and the goal is just to minimize flex to keep it from cracking.

If it was me I would just mold in metal or wood reinforcement into the inside and ceiling of the fiberglass, but I could care less about appearance. You can see part of the 'Nest frame in this photo. There are 4 rectangular tubes, one at each corner, connected along the side with horizontal members over the windows. The whole thing is then covered in structural fiberglass.

'91 Pickup - Imelda / '08 Tacoma TRD - Donna
'09 Kawasaki KLR650
'98 Rhygin Juke SS / '12 Gunnar Rockhound 29 / '16 REEB Dikyelous

"Our task must be to free ourselves from this prison by widening our circle of compassion to embrace all living creatures and the whole of nature in its beauty. Nobody is able to achieve this completely, but the striving for such achievement is in itself a part of the liberation and a foundation for inner security. " --Albert Einstein
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