These are the
key design factors that go into every LEER fiberglass truck cap and
tonneau, and while the final product may look simple, it is the result
of rather sophisticated engineering and manufacturing processes. Here
is a brief description of just what goes into the manufacturing of
LEER fiberglass products:
Precise
molds are the first critical ingredient . . .
Extraordinarily
accurate molds are fabricated, using computer-aided design and skilled
handcraftsmanship, by the LEER mold shop, before being released
to the production teams at the three LEER plants (in Elkhart, Indiana;
Milton, Pennsylvania; and Woodland, California). While molds may
last for years, they are also subject to constant maintenance, to
preserve their mirror-finish surfaces and dimensional accuracy.
Literally hundreds of molds are maintained by LEER, and each mold
is inspected, cleaned, waxed, polished, and prepped for use each
and every time it is put into production.
The
first element in the mold: "gelcoat"
The first element
put into the prepared mold for your cap or tonneau is a layer of
"gelcoat," a synthetic polymer designed to flow smoothly
into every part of the mold, in a thin (2-3 mils) but durable layer
that will form the smooth-finished outside surface of your cap or
tonneau. 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, LEER gelcoat comes
in three colors (white, light grey and dark grey), designed to provide
the best coverage, based on the color of the paint that will be
used.
A
ceramic plastic strengthens key stress areas
Next, a spray
application of ceramic plastic is added to strengthen key stress
areas. This ceramic coat adds hardness and helps the cap or tonneau
resist cracking along the cut edges.
The
key structural component: random-strand fiberglass
The next step
adds the key structural component, random-strand fiberglass. Long,
thin filaments of glass fibers are chopped to lengths averaging
1 to 2 inches long, and are combined with resin (another 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 skilled operators who control the thickness of the application
to within a few hundredths of an inch. If the fiberglass layer is
too thick, it is too heavy and too rigid; too thin and it won't
have the required strength.
Hand-rolling
of the fiberglass eliminates air bubbles and voids
While the combination
of glass and resin is still curing, it is meticulously rolled out,
another hand operation that eliminates any air that may be trapped
in the fiberglass layer. At this time, too, reinforcements of marine
grade plywood and metal are added to the mold, where they will be
encased in another layer of glass and resin. These reinforcements
make it possible for LEER to add racks, locksets, hinges, storage
boxes, and other bolted-on hardware parts that would otherwise stress
the fiberglass.
A
lightweight but resilient reinforcement layer is added
A layer of "tri-cel"
honeycomb or striated fiber is added at this time, too. When soaked
with resin, this internal stiffener provides an incredibly hard,
durable, and resilient layer of reinforcement that adds significant
strength with minimum weight to the roof area of the cap or tonneau.
Additional
fiberglass is "hand-laid" into dramatic curves and complex
shapes
Also, depending
upon the design, additional fiberglass is added in the form of hand-laid
sheets of "woven roving." This application further strengthens
areas of the cap or tonneau that have dramatic curves and complex
shapes. Each step of the way, each layer of fiberglass and resin
is rolled out, just like the first, to ensure there are no air voids
in the structure.
A
catalyst causes the fiberglass to cure and harden
With the fiberglass
and reinforcing work complete, caps and tonneaus are set aside so
the curing process generated by the catalyst can continue. Soon
after it is complete, the new caps and tonneaus are released from
the molds and trimmed of excess material. The production process
is far from complete, however.
Critical
eyes inspect every piece; fiberglass rails are added to caps
Each fresh part
is individually inspected by experienced eyes, and any surface flaws
in the molded part are noted so they can be corrected. Caps go through
yet another round of fiberglass production, where the fiberglass
"rails" that mount to your truck bed are molded and mated
to the caps, using additional hand-applied layers of fiberglass
and resin. Caps and tonneaus are mounted on individual skids so
they can move through the assembly process with a minimum of handling.
Window
and door openings are carefully cut; headliners are added
Caps are also
led to the cutting operation, where the openings for windows and
doors are first carefully marked, then precisely routed, so they
can accept any of LEER's wide range of windows and doors. Our commercial
carpet headliner option is installed at this point, too.
Inspections
continue, surfaces are refined before parts are painted in a clean,
controlled environment
More inspections
and further preparation are performed as caps and tonneaus are led
to sophisticated paint spray booths where lighting, air pressure,
humidity, temperature and filtration provide an ideal painting environment.
Using Dupont Automotive paints, and OEM-matching paint formulas,
highly trained painters apply a basecoat of color, then a clearcoat
for UV protection and gloss. Each cap and tonneau is then sent through
temperature-controlled heat tunnels, to cure and set the fresh paint.
Hardware
is added, caps are water-tested
Windows, doors,
locks, latches, hinges, seals, and a wide range of other hardware
and accessory options are added at this point. It is here that the
built-in reinforcements of metal and wood are so critical. The famous
"LEER" logo is also applied at this time. All caps are
water-tested too, using either a water shower booth or ultrasonic
leak-testers.
All
products must pass a final approval before they can be released for
shipment
Once the assembly
process is complete, each and every unit leaving the "back
door" of the plant is subjected to a final inspection. Shipment
is scheduled only after each cap and tonneau has passed that inspection.
The result of
the LEER manufacturing process is a truck cap or tonneau that is everything
you want it to be:
light,
strong, resilient, precise and beautiful!
Learn
more about the history and heritage of the LEER organization by clicking
here.
