Has this ever happened to you? You’re driving down the highway in your pickup truck, happy as can be. Suddenly, you hear a loud popping noise coming from the back. Uh oh. You pull over and peek under your tonneau cover to find that one of the plastic strips has broken off. Now part of your tonneau is flapping in the wind, and your truck bed is exposed. What a pain!
Broken plastic strips are a common issue on tonneau covers. The constant opening and closing, plus exposure to sun, wind, and rain, takes a toll over time. When those thin plastic pieces crack and break, it can leave your tonneau cover unusable and your truck bed unprotected.
Luckily, with the right materials and some DIY know-how, you can fix those broken tonneau strips yourself. In this comprehensive guide, we’ll walk through the steps to repair broken plastic strips and latches on your tonneau cover. Let’s get that baby fixed up and back to keeping your cargo covered!
What supplies will I need to fix my tonneau’s broken plastic strips?
Before you start the repair process, you’ll want to make sure you have the necessary supplies on hand. Here’s what you’ll need:
- Tonneau cover repair kit – You can purchase a kit made specifically for repairing tonneau covers that will contain adhesive patches, sealants, replacement latches, and any hardware needed. Amazon, Walmart, auto parts stores, or your tonneau manufacturer are good places to find a kit.
- Rubbing alcohol – This is used to clean the repair area to help the adhesive stick properly.
- Rags – You’ll need some clean cloths or rags to wipe down the repair area. Paper towels can work too.
- Sandpaper – Light sanding can help the adhesive grip if the plastic is smooth.
- Utility knife – To trim the adhesive patches to size.
- Masking tape – Helps hold patches in place while adhesive dries.
- Gloves – Protect your hands from adhesives. Nitrile gloves work best.
Getting the right supplies will make your tonneau cover repair go much smoother. Now let’s get to those step-by-step instructions!
Step 1: Assess the damage
Before you start fixing anything, you need to take a close look at exactly what is broken on your tonneau cover. There are a few main plastic components that commonly break:
Broken Latches
Tonnesu covers secure to the truck bed with plastic latching mechanisms. The latches are often the first thing to break from repeated opening and closing. Examine all the latches along the tonneau’s rails. If any are cracked or broken, they will need replaced.
Torn Seals
The vinyl seals that run along the rails of your tonneau help keep out water and debris. Check for any torn or detached sections that could be letting in the elements.
Split Support Bows
If your tonneau has a soft roll-up cover, it likely relies on thin plastic bows to hold its shape. Over time, these can bend, crack, and split. Inspect the length of each bow for damage.
Ripped Pull-Straps
Some tonneaus have heavy duty pull-straps with plastic brackets to make it easier to open and close the cover. The straps often get ripped out of the plastic brackets.
Once you’ve identified all the broken parts on your tonneau, you can move on to repairing them.
Step 2: Thoroughly clean the repair area
Now that you know what needs fixed, you’ll need to clean the surface around the damage to prep for repairs. Here’s how:
- Give the tonneau cover a preliminary cleaning with soap and water if it’s really dirty.
- Use rubbing alcohol and clean rags to wipe down the area around the broken plastic components. The alcohol will remove any grease, dirt, or debris so the adhesive can stick.
- If there are any rust spots or paint flaking off near the broken area, sand lightly with fine grit sandpaper. This roughs up the surface a bit for better adhesion.
- Make sure the area is completely dry before moving to the next step.
Proper surface prep is extremely important for the repair patches, seals, and latches to bond securely. Take your time with this cleaning step.
Step 3: Apply adhesive patches
Once prepped, it’s time to start patching things up. For broken latches, seals, straps, or support bows, simply stick on adhesive patches:
- Cut patches to size using utility knife. Make sure to round off the edges for easy installation.
- Peel backing off adhesive patch. Many are like large band-aids.
- Carefully align patch over damaged area and press down firmly.
- Use masking tape to hold the patch in place if needed while the adhesive cures.
- For support bows, sandwich the split section between two patches.
- Clamps can also help apply even pressure as the adhesive sets.
Follow the cure times recommended on the adhesive package. Some may take up to 24 hours to fully bond before using the tonneau cover. Once cured, your patches should hold up to normal tonneau use.
Step 4: Replace broken latches
If the plastic latches along the rails are shattered or weak, they will need fully replaced for proper function. Luckily, tonneau latch kits are easy to install:
- Start by removing old latches. There may be screws, pop-rivets, or tabs securing them.
- Clean latch recesses on rail with alcohol and sandpaper to remove debris and rough up surface.
- Peel adhesive backing on new latch and stick in place, applying firm pressure.
- Some latches also have mechanical fasteners for a stronger hold. Use any included screws or rivets.
- Let adhesive fully cure before using new latches. Give them a test open and close to ensure smooth operation.
Swapping out those busted latches for fresh, strong ones will get your tonneau opening and closing smoothly once again.
Step 5: Seal any gaps or holes
While you have your tonneau cover disassembled for repairs, it’s a great time to check for any other problem spots like light poking through gaps or drilled holes from previous accessories. Seal these up with adhesive patches or vinyl sealant to prevent dust and moisture getting in your truck bed.
- Identify any gaps along the rails or holes in the tonneau cover.
- Clean and sand areas to rough up surface for maximum adhesion.
- Apply adhesive patches to small gaps and holes. For larger areas, use a liquid sealant or vinyl cement along the rail.
- Allow all seals to fully cure before reinstalling repaired tonneau.
With leaks and gaps sealed up, your tonneau will keep the elements out of your truck bed once again.
Step 6: Reinstall tonneau cover
This is the moment of truth when you get to put your freshly repaired tonneau cover back on your truck. Just follow the reverse steps from when you removed it:
- Set the tonneau cover in place on the truck bed, aligning the rails with the bed sides.
- Close the tailgate to hold it in place temporarily.
- Attach the latching mechanisms by lifting the handles and hooking clamps over latch pins.
- For a roll-up tonneau, rotate bows into position and secure with clips.
- Fully latch each side and push down on cover to seat rails against bed.
- Operate latches a few more times to make sure they engage smoothly.
- Give yourself a pat on the back for a job well done!
It may have been a pain, but fixing those busted tonneau components yourself saved you a ton of cash versus buying a replacement. Now get back on the road with your truck bed protected from the elements once again.
Common Tonneau Cover Problems and Fixes
Beyond broken plastic strips, there are a few other common tonneau issues that can pop up. Here are some handy tips for getting them fixed:
Problem: Rips or holes in vinyl tonneau cover fabric
Fix: Clean area thoroughly, apply adhesive patch, and seal edges with vinyl sealant. Larger rips may need professional patching.
Problem: Side rails have come loose and tonneau won’t stay closed
Fix: Realign rails and use C-clamps to hold in place. Drill new fastener holes if needed and reseat rails with silicone caulk.
Problem: Snaps, zippers, or fasteners have broken loose
Fix: Replace individual fasteners with new ones secured with rubber cement or adhesive patches.
Problem: Tonneau cover is stuck open or closed
Fix: Apply lubricant to latch mechanisms and release handles. Work mechanisms back and forth to loosen up. Replace if too damaged.
Problem: Leaking water due to damaged seals
Fix: Remove old seals and clean rail areas. Install new vinyl seals with rubber cement and let fully cure.
Knowing these quick fixes will keep your tonneau cover in working order for years down the road!
When to Call in a Professional for Tonneau Repairs
While many tonneau cover repairs can be done yourself at home, there are some instances where you’re better off taking it to the experts:
- If the cover framework itself is bent or damaged
- For extensive tearing of vinyl fabric that needs re-welded
- If the tonneau rail has come completely unattached from the truck bed
- If latch damage is so severe the tonneau won’t stay closed
- If you don’t have the time or patience for DIY repairs!
Repair costs will vary based on needed work, but are typically less than buying a brand new replacement tonneau. Get some quotes from local auto body and tonneau specialty shops to find the best deal.
Knowing when to call in a professional tonneau repair versus tackling it yourself will ensure the job gets done quickly and correctly.
Maintain Your Tonneau Cover to Prevent Future Damage
They say “an ounce of prevention is worth a pound of cure.” That’s definitely true when it comes to tonneau cover maintenance. Here are some tips to keep your tonneau in good shape for years:
- Inspect latches and hinges monthly for any cracking or wear. Lubricate with WD-40 if stiff.
- Wash vinyl tonneau covers with soap and water monthly to prevent UV damage.
- Avoid stepping directly on the tonneau or letting heavy objects fall on it.
- Park in the shade whenever possible to limit vinyl cover sun exposure.
- Keep the tonneau rails lubricated so they slide easily when opening/closing.
- Promptly replace any fasteners that become loose or damaged.
- Don’t take your tonneau through automatic car washes. Hand wash only.
- Apply UV protectant spray yearly to protect vinyl tonneau fabric.
With proper care and maintenance, your tonneau cover should last for many years and miles. But even the most well-cared for tonneaus may need repairs eventually. Now you have the knowledge and skills to fix those broken plastic strips or latches yourself – and save some serious cash in the process!
