How Your ProTops Product is Manufactured
Your
ProTops
fiberglass
Camper
Shell
or
Tonneau
Cover
is
a
fascinating
combination
of
art,
science
and
technology.
Here’s
a
description
of
how
it
is
manufactured.
Precision molds are the most critical component
Extraordinarily
accurate
molds
are
fabricated
by
skilled,
hand-craftsmanship
in
the
ProTops
mold
shop
before
being
released
to
the
production
teams
in
the
ProTops
manufacturing
plant
in
San
Bernardino,
California.
While
molds
may
last
for
years,
they
also
require
constant
maintenance
to
keep
their
mirror-finish
surfaces
and
dimensional
accuracy.
Literally
hundreds
of
molds
are
maintained
by
ProTops,
and
each
mold
is
inspected,
cleaned,
waxed,
polished, and prepped each and every time it is used.
The first material in the mold is gelcoat
The
first
layer
in
the
prepared
mold
for
your
cap
or
tonneau
is
a
gelcoat,
a
synthetic
polymer
designed
to
flow
smoothly
into
every
part
of
the
mold.
The
gelcoat
is
a
thin
(2-3
mils)
but
durable
layer
that
will
form
the
hard-smooth-finished
outside
surface
of
your
camper
shell
or
tonneau
cover.
It
is
the
gelcoat
that
will
be
prepped
for
painting
and
will
receive
the
exterior
paint
finish
you
see.
Because
it
is
directly
under
the
painted
surface,
ProTops™
uses
grey gelcoat, designed to provide the best contrast for the paint that will be sprayed.
Random strand fiberglass is the key structural component
The
next
step
adds
the
key
structural
component,
random-strand
fiberglass.
Thin,
long
filaments
of
glass
fibers
are
chopped
into
lengths
averaging
1
to
2
inches
long,
and
are
combined
with
resin
(an
advanced
polymer
plastic)
and
a
catalyst
that
enables
the
combined
ingredients
to
harden
and
cure.
This
layer
of
chopped
glass
and
resin
is
applied
by
expert
operators
who
control
the
thickness
of
the
application
to
within
a
few
hundredths
of
an
inch.
If
the
fiberglass layer is too thin and it won't have the required strength. If it is too thick, it is too heavy and too rigid for this application.
Hand rolling of the fiberglass eliminates air pockets and bubbles
While
the
combination
of
glass
and
resin
is
still
curing,
it
is
meticulously
rolled
out
by
hand
to
eliminate
any
air
that
may
be
trapped
in
the
fiberglass
layer.
At
this
time,
reinforcements
are
added
to
the
mold,
where
they
will
be
encased
in
another
layer
of
glass
and
resin.
These
reinforcements
make
it
possible for ProTops to add lock hardware, hinges, storage boxes, racks, and other bolted-on parts that would otherwise stress the fiberglass.
A lightweight reinforcement layer is added
A
layer
of
"multi-cell"
honeycomb
is
glassed
in
at
this
time.
When
this
internal
stiffener
comes
in
contact
with
the
resin,
it
provides
an
incredibly
hard,
resilient
and
durable
layer
of
reinforcement
that
adds
significant
strength
with
minimum
weight
to
the
roof
area
of
the
camper
shell
or
tonneau
cover.
Additional
fiberglass
is
added
in
complex
curves
and
shapes.
Also,
depending
upon
the
design,
additional
fiberglass
may
be
added
in
the
form
of
hand-laid
sheets
of
"woven
fiberglass
cloth."
This
application
further
strengthens
areas
of
the
camper
shell
or
tonneau
cover
that
has
complex
curves
and
shapes.
After each step, each layer of resin-infused fiberglass is rolled out to make sure there are no air pockets in the structure.
Catalyst cures the fiberglass resin
With
the
fiberglass
and
reinforcing
work
complete,
Camper
Shells
and
Tonneau
Covers
are
set
aside
so
the
curing
process
started
by
the
catalyst
can
continue until complete curing has occurred.
Critical scrutiny of every piece
Fiberglass
outside
edges
are
added
to
the
Camper
Shells
&
Tonneau
Covers.
Each
fresh
part
is
individually
inspected
by
experienced
eyes,
and
any
surface
flaws
in
the
molded
part
are
corrected.
Camper
Shells
go
through
yet
another
round
of
fiberglass
production,
where
the
fiberglass
rails
that
mount
to
your
truck
bed
are
molded
and
mated
to
the
Camper
Shells,
using
additional
layers
of
fiberglass
and
resin.
The
following
day,
the
new
Camper
Shells
and
Tonneau
Covers
are
removed
from
the
molds
and
excess
fiberglass
material
is
trimmed
off.
Camper
Shells
and
Tonneau
Covers
are
mounted
on individual assembly carts so they can move through the assembly process with minimal handling.
Automotive, multi-stage painting adds gorgeous color
Inspections
continue
and
surfaces
are
refined
before
parts
are
painted
in
a
clean,
controlled
environment.
More
inspections
and
further
preparations
are
performed
as
Camper
Shells
and
Tonneau
Covers
are
led
to
sophisticated
paint
spray
booths
where
lighting,
air
pressure,
humidity,
temperature
and
filtration
provide
an
ideal
painting
environment.
Using
automotive
quality
paints
and
OEM-matching
paint
formulas,
highly
trained
painters
apply
a
base
coat
of
color,
then
a
clear
coat
for
UV
protection
and
gloss.
Each
Camper
Shell
and
Tonneau
Cover
is
then
sent
through
temperature-controlled
heat
tunnels
to
cure
and
set
the
fresh
paint.
Window
and
door
openings
are
carefully
cut,
headliners
are
added.
Shells
are
moved
to
the
cutting
operation,
where
openings
for
windows
and
doors
are
carefully
marked,
then
precisely
cut,
so
they
can
accept
any
of
ProTops'
wide
range
of
windows
and
doors.
Our
optional, commercial grade marine carpet headliner is installed at this point.
Hardware is installed. Camper Shells are water tested for leaks
Windows,
doors,
locks,
latches,
hinges,
seals,
and
a
wide
range
of
other
hardware
and
accessory
options
are
added
at
this
stage.
Critical,
built-in
reinforcements are installed and the famous ProTops decals are applied. All Camper Shells are water-tested to ensure there are no leaks.
All products pass final approval
Once the assembly process is complete, each and every unit leaving our plant undergoes a final inspection. Shipment is scheduled only after each
Camper Shell and Tonneau Cover has passed inspection. The result of the ProTops manufacturing process is a Camper Shell or Tonneau Cover that is
everything you want it to be: light, strong, resilient, precise, beautiful and long-lasting!
ProTops™ Delivery
The connection between ProTops and your local ProTops Dealer. ProTops operates its own trucks towing custom-designed trailers delivering ProTops
Camper Shells and Tonneau Covers to our network of dealers.
Dealer Prep
ProTops
Dealers
often
clean
products
that
show
road
dust,
etc.
from
their
long
journey
from
the
plant.
They
remove
any
shipping
plastic
and
prepare
your
Camper
Shell
or
Tonneau
Cover
for
installation.
Installation
Your
ProTops
Dealer
carefully
prepares
your
truck
for
installation,
using
highly
specialized
clamps
to
secure
your
new
Camper
Shell
or
Tonneau
Cover
to
your
truck.
The
Dealer
makes
critical
adjustments
to
hinges,
locks,
latches
and
other
mechanical
features
that
require
tight
tolerances.
The
Dealer
connects
required
electrical
connections
for
the
third
brake
light
and
other
optional
12-V
accessories
are
connected.
After
a
final
inspection
and
test
of
the
operation
of
the
features
of
your
new
ProTops,
it's
yours
to
enjoy
for
years
and
years
to
come. . .
Manufacturing
