Truck cap and method of making a truck cap using a closed-cavity bag molding process

A closed cavity bag molding process for manufacturing a truck cap, the process comprising:

• providing a female mold shaped to form a top of a truck cap, the female mold having a roof portion, a continuous sidewall extending upward from the roof portion, and a flange extending laterally outward from an upper edge of the sidewall, the flange extending continuously around the upper edge of the sidewall, the flange defining a slot spaced from and extending continuously around the upper edge of the sidewall, wherein at least one seal port is positioned in the slot;
• placing a first layer of fiber mat in the mold so that the first layer covers the roof portion, the sidewall, and at least a portion of the flange of the mold and so that a peripheral edge of the first layer is adjacent the flange and spaced apart from the slot;
• placing a reinforcement on top of at least a portion of the first layer so that the reinforcement is positioned over at least a portion of the roof portion of the mold;
• placing a second layer of fiber mat over the first layer and the reinforcement so that a peripheral edge of the second layer is adjacent the flange and spaced apart from the slot;
• applying a bleeder strip to the flange so that the bleeder strip covers the peripheral edge of at least one of the first layer or the second layer and secures the peripheral edge of the at least one of the first layer or the second layer to the flange, the bleeder strip extending continuously around the flange;
• providing a flexible cover having an outer side and an opposite inner side, at least one injection port extends from the outer side to the inner side, and at least one vacuum port extends from the outer side to the inner side, the cover comprising a rib that extends outward from the inner side, the rib extending continuously around the cover adjacent a peripheral edge of the cover, the inner side of the cover defining a vent channel that is spaced laterally inward from the rib, the vent channel in fluid communication with the at least one vacuum port;
• laying the flexible cover over the second layer, the bleeder strip, and a portion of the flange so that the rib is positioned in the slot and the vent channel overlies the bleeder strip;
• actuating at least one vacuum, the at least one vacuum being in fluid connection with the at least one seal port so that the vacuum pulls the rib into the slot to place the cover in sealing engagement with the flange, the at least one vacuum further being in fluid connection with the at least one vacuum port so that the vacuum draws air out of the first and second layers through the bleeder strip and the vent channel;
• and
• delivering resin through the at least one injection port, the resin impregnating the first and second layers as the vacuum draws air through the at least one vacuum port.