A retractable tonneau cover is a popular truck bed cover that rolls up into a canister at the front of the bed. Retractable covers provide easy access to the bed and help protect cargo from weather and theft. However, the vinyl material can develop cracks over time. Cracks allow water, dirt, and debris to enter the bed, damaging your cargo. So it’s important to repair cracks as soon as you notice them. Here are the best ways to fix cracks in a retractable tonneau cover.
What causes cracks in retractable tonneau covers?
Retractable tonneau covers crack for several reasons:
Exposure to sun and weather
The vinyl material is vulnerable to UV rays, heat, cold, rain, snow, and wind. Long-term exposure causes the material to dry out and crack.
Normal wear and tear
The cover rolls up and down hundreds of times, which stresses the vinyl. Mounting hardware also creates stress points. These factors cause tiny cracks to form, which expand over time.
Improper cleaning
Using harsh chemicals, abrasive brushes, or power washing weakens the vinyl and causes cracking.
Accidents and impact
Dropping heavy objects on the cover, or trailers scraping across it, can immediately cause rips and tears.
Can you repair cracks in a retractable cover?
Yes, it is possible to repair cracks, depending on the size and location:
- Small cracks less than 2 inches long can often be repaired.
- Cracks longer than 2 inches are harder to fix.
- Cracks along seams and edges are more difficult to repair neatly.
- Repairing cracks through the middle of a panel is easier.
- Severe cracks or punctures might require replacing panels.
With the right materials and techniques, you can repair minor cracks yourself and restore the cover’s appearance and function.
Step-by-step guide to repairing small cracks
Here is a DIY guide for repairing short cracks up to 2 inches long anywhere on the vinyl:
1. Clean the area
Use a mild soap and water to clean the vinyl around the crack. This helps the repair adhesive stick properly.
2. Apply rubbing alcohol
Wipe rubbing alcohol over the crack and surrounding area. This removes any remaining dirt or grease.
3. Prepare the patch material
Cut a patch slightly larger than the crack from excess vinyl or a vinyl repair kit. Round the corners to prevent peeling.
4. Apply adhesive
Use a vinyl adhesive made for tonneau covers. Apply a thin, even layer over the patch and crack.
5. Position the patch
Place the patch over the crack, smoothing it from the center outward. Press firmly to adhere.
6. Apply pressure
Once positioned, rub the entire patch with your thumb to maximize adhesion.
7. Clamp the patch
Use small binder clips or clamps over the patch. This keeps pressure on while the adhesive dries.
8. Allow to cure
Leave clamps for at least 24 hours to fully cure. Avoid disturbing the cover during this time.
9. Seal and protect
Once cured, apply a vinyl protectant to help blend the patch. Reapply protectant regularly to prevent future cracks.
With this easy patch repair, you can fix small cracks and restore the appearance of your retractable tonneau cover.
How to repair larger cracks
For cracks longer than 2 inches, a more extensive repair is required:
1. Clean and dry the area
Scrub surrounding vinyl with soap and water, then wipe with alcohol to prepare for repair.
2. Apply adhesive promoter
Brush a vinyl adhesion promoter onto the crack and surrounding area. This helps the repair take hold.
3. Repair torn edges
If the crack has ragged edges, apply a thin layer adhesive and smooth with a putty knife. Let cure completely.
4. Fill the crack
Force flexible vinyl filler deeply into the crack. Smooth flush with a putty knife.
5. Apply patch
Cut a patch extending 2 inches beyond each side of the crack. Apply adhesive and position.
6. Work from center outward
Once positioned, rub the center outward to prevent trapping air and maximize adhesion.
7. Apply pressure
Use small clamps directly over the crack to apply constant pressure as the adhesive cures.
8. Allow extended curing
Leave clamps on for 48 hours before removing to ensure strong repairs.
9. Add protective coating
Once fully cured, apply a UV-resistant vinyl protectant to help blend the patch and prevent future cracks.
While labor intensive, this method can successfully repair cracks up to 8 inches long across vinyl panels.
How to repair cracks at panel seams
Cracks often develop along seams where vinyl panels join:
1. Thoroughly clean seam
Use a vinyl cleaner and scrub brush to deep clean the damaged seam area. Rinse and dry completely.
2. Loosen panels
Remove any screws joining the panels. Carefully pry apart just enough to access the seam.
3. Apply seam sealer
Force vinyl seam sealer into the crack along the length of the seam. Smooth with a putty knife.
4. Allow to cure overnight
Clamp panels together. Let the seam sealer fully harden before reinstalling screws.
5. Seal and protect
Once cured, apply vinyl protectant spray to help blend the repaired seam. Reapply regularly.
Taking panels apart slightly allows a permanent seam repair. Be very careful not to damage panels when prying apart.
How to repair cracks at mounting holes
The screws used to mount a retractable cover cause stress that cracks vinyl:
1. Remove screw and hardware
Take out the screw, washer, and plastic retainer causing the crack.
2. Clean mounting hole
Use a mild detergent on the cracked hole and surrounding vinyl. Rinse and wipe with alcohol.
3. Enlarge hole slightly
Use a sharp utility knife to cut the hole 1/8 inch larger all around. This removes damaged edges.
4. Apply edge sealer
Brush vinyl edge sealer around the enlarged hole to reinforce it. Let fully cure.
5. Replace hardware
Insert new wider washers and a screw, along with a plastic retainer. Tighten gently and evenly.
6. Check for leaks
Spray the mounting hole area with water to ensure no leaks. Allow to dry fully.
7. Apply protectant
Coat the area with vinyl protectant to blend old and new vinyl. Reapply protectant regularly.
Enlarging the mounting hole can permanently repair cracks while still securely mounting the cover.
How to repair large rips, tears, or punctures
Major damage requires replacing entire vinyl panels:
1. Order a replacement panel
Find the manufacturer part number for your tonneau model. Order an exact replacement panel.
2. Remove the damaged panel
Take out all the screws and mounting hardware. Very carefully pry and detach the panel.
3. Transfer useful parts
Move over any undamaged latches, hinges, or retainers to the new panel.
4. Test fit new panel
Do a dry run installing the new panel to ensure proper fit. Make any adjustments.
5. Clean and prep
Wipe the underside of the new panel and existing cover with alcohol to prep for adhesion.
6. Apply adhesive
Run a bead of panel adhesive along the underside of the replacement panel.
7. Install new panel
Position the panel precisely. Starting at one end, press and smooth firmly. Attach hardware.
8. Seal the edges
Caulk along the edges to prevent leaks. Let the caulk fully cure before using cover.
9. Weatherproof
Treat the new vinyl with UV protectant to match the fading of the older vinyl.
While labor intensive, panel replacement provides a permanent repair for major damage to your retractable cover.
Tips for preventing future cracks
To minimize cracks in the future:
- Park in shade to limit sun exposure when possible
- Open cover to vent heat on hot days
- Use extreme care when cleaning with water or chemicals
- Avoid dragging objects across the cover
- Wax the cover 1-2 times per year with UV protectant
- Check for cracks after storms and repair immediately
- Adjust cover occasionally to release stress points
- Lubricate hinges and slides regularly to prevent excessive wear
With proper care and maintenance, your retractable tonneau cover can last for years without cracks. But if cracks do occur, use the repair methods outlined to restore your cover to look and function like new again.
Frequently Asked Questions about Repairing Retractable Tonneau Covers
What is the best way to stop a small vinyl crack from spreading?
To stop a small crack from growing, clean it thoroughly with alcohol then apply a liberal amount of vinyl sealant like RVT into the end of the crack. Allow to fully cure before using the cover. The flexible sealant prevents movement so the crack cannot spread.
Will Flex Tape work to repair vinyl tonneau cover cracks?
Flex tape is not recommended. It does not adhere well long-term on vinyl surfaces exposed to weather. Instead, use vinyl patch material and vinyl-specific adhesives made for tonneau cover repair. These are flexible and durable when exposed to sun, rain, and movement.
Can you apply a piece of old vinyl over a crack as a patch?
Yes, you can cut a patch piece from unexposed underside areas of your old cover if matching your vinyl color exactly. This avoids visible seams from mismatched colors. Use a quality vinyl adhesive to bond the patch firmly over any cracks larger than 2 inches.
What is the best way to repair a crack between vinyl panels?
For cracks along seams between retractable cover panels, the best repair method is to separate the panels slightly. Thoroughly clean inside the crack, force vinyl seam sealer deep into the crack, clamp panels together, and let cure 48 hours. The seam will be permanently sealed.
Is Gorilla tape safe for repairing tonneau cover vinyl?
Gorilla tape adhesive will damage vinyl tonneau covers. The glue has solvents that react with vinyl and cause it to warp, wrinkle, and break down over time. Use vinyl-specific adhesives without harsh solvents that remain flexible after curing.
Can you apply a fiberglass repair patch to a vinyl tonneau cover?
Fiberglass repair products should never be used on vinyl covers. The resins interact and damage the vinyl material, quickly causing more cracks and deterioration. Only use materials specifically made for repairing vinyl or plastic.
Is there a quick fix for a small crack in my vinyl tonneau?
For very small cracks less than 1 inch, you can apply a thin coat of clear vinyl sealant as a quick fix. Make sure to work it deep into the end of the crack. This flexible sealant prevents water getting in and stops the crack spreading. It blends in better than a patch for very minor cracks.
How do I repair a crack around rusted mounting bolts?
If mounting bolt holes are cracked and rusted, enlarge the holes to remove all cracked vinyl. Grind off the rust and install new stainless bolts with wider washers. Clean the area thoroughly then seal around the new holes with waterproof vinyl sealant to prevent leaks.
Should I use super glue to repair tonneau cover cracks?
No, super glues and epoxies do not properly adhere long-term to flexible vinyl. As the cover moves and rolls, the inflexible glue will detach causing more cracking. Only use vinyl patch kits with adhesives designed to bond vinyl for durable repairs.
What is the best way to stop cracks from reappearing after repairing?
To stop repaired cracks from splitting open again, apply a vinyl protectant wax or UV coating over the areas after they are fixed and cured. Reapply this vinyl treatment 2-3 times per year to keep the vinyl supple and prevent recurrence of cracks.
How do I repair a puncture or slice in my vinyl tonneau cover
For slits, punctures, or other major damage, purchase a replacement vinyl panel from the manufacturer. Remove the damaged panel, clean off old adhesive, install the new panel with panel adhesive caulk, and weatherproof the vinyl. This will permanently repair significant tears or holes.
Repairing cracks and damage helps preserve your expensive retractable tonneau cover. Use vinyl-specific patches, adhesives, and treatments to properly fix cracks and prevent water intrusion, further tearing, and impact on your truck bed.
