Door frame construction for pickup truck cap and method of manufacture

A trapezoidal door and frame assembly and method of manufacture in which the assembly is constructed of a top horizontal frame member having the ends thereof arcuately shaped to conform with the radius of the upper corners of the cap. The ends are formed without deforming the flanges extending from the outer face of the frame member by removing, in a novel and unique method, portions of the flanges which permits cutting the ends of the frame member along a radius which matches the upper corners of the cap. This top door frame construction permits mounting the frame member closer to the top of the cap, thus providing a larger access opening and door in the rear of the cap.

This invention relates to a door and frame assembly for pickup truck caps 
and to a method for forming the top horizonal frame member for the same. 
BACKGROUND OF THE INVENTION 
Enclosures or so-called "caps" for the bed of pickup trucks have become 
very popular. Caps of this type generally have included sides with arcuate 
corners to match the cab of the truck. At the rear of the cap a door is 
provided which covers the space between the tailgate and the cap top wall. 
This door swings upwardly and is mounted on a frame, such door and frame 
assembly being generally manufactured by specialty companies who sell the 
assembly to the truck cap manufacturer. 
The caps of various manufacturers have cap sides inclined at different 
degrees to align the cap sides with the cab of the truck. Accordingly, 
suppliers offer assemblies with the sides of the door and frame at 
different angles to fit the caps. However, economics dictates that the 
number of such differently angles assemblies be limited and thus in 
general the different degree doors offered by the industry are 11, 15 and 
17 degrees. This economic limitation has assisted in creating a problem 
that has plagued the industry for years primarily because of the 
construction and shapes of the top horizontal door frame member which 
essentially has become the standard for the industry. 
The structure and shape of the top door frame member that causes the 
problem is that it is an extruded metal piece having a flat part with one 
surface adapted to abut against the rearward face of a cross support 
forming a part of the cap frame at the rear thereof. The opposite surface 
has an integral hinge flange of a complicated configuration extending 
rearwardly of the cap and adapted to telescopingly receive a similarly 
configurated hinge flange formed at the top edge of the door. The opposite 
surface also has a channel protrusion extending therefrom for receiving a 
trim strip that hides the fasteners which attach the door frame to the 
cross support of the cap frame. 
Before our invention, the ends of the top door frame member have been cut 
along a straight vertical line which causes the extreme upper corner of 
the frame member to extend into and interfere with the molding formed on 
the top and sides of the door unless such corner is snipped off by the cap 
manufacturer or the cross support of the cap frame is moved downwardly 
thus reducing the size of the door. 
Snipping off the corner is very unsatisfactory because it produces an 
unsightly appearance and also leaves a ragged sharp edge on which a person 
can be scratched or cut. Moving the cross support of the cap frame 
downwardly restricts the space between such cross support and the top edge 
of the tailgate leaving less space to enter the cap and also reducing the 
size of the door. Further, the appearance is adversely affected because 
the top of the door frame is located a greater distance from the top of 
the cap. 
The industry has been attempting for years to solve the above problem but 
prior to our concept it has remained insolved. 
The appearance of the standard trapezoidal door as above described, also 
has much to be desired because the ends are straight and do not in any way 
blend in with the arcuate shaped silhouette of the cap. As a result, 
so-called "radius" door and frame assemblies have been developed. Such 
radius assemblies form the sides and top of a bent metal frame member that 
more nearly conforms to the shape of the cap. However, the strength of 
trapezoidal doors is far superior and accordingly radius doors are not 
generally used where strength is a factor. 
SUMMARY OF THE INVENTION 
In accordance with our invention, we provide a trapezoidal door and frame 
assembly in which the ends of the top horizontal frame member are 
arcuately shaped with a radius substantially conforming to the radius of 
the cap molding and thus substantially conforming to radius of the upper 
corners of the cap. As a result, the assembly blends in with the cap. 
In addition, our construction eliminates the upper protruding corners of 
the door frame member thus avoiding interference with the molding around 
the door. This permits the cross support on the cap which supports the 
door frame member to be moved upwardly to increase the size of the door 
and the size of the opening into the cap. 
We accomplish the above advantages by providing a novel construction of the 
top horizontal door frame member. More specifically, at the ends of the 
frame member, the hinge flange and channel protrusion are stripped from an 
end portion of the upright flat part of the frame member, i.e., the part 
that is secured to the cross support of the cap frame. This permits the 
stripped portion of the flat part to be cut along an arc conforming 
substantially to the arc of the top corners of the cap. 
The stripping of the hinge flange and channel protrusion is performed by a 
novel method using a novel die and cutting tool assembly which severs or 
shears a portion of each of the flange and protrusion along lines on the 
plane of the outer surface of the flat part to which they are attached; 
and cutting the same away from the part so as to completely remove the 
severed portion from the part. This leaves an end portion of the flat part 
which can be cut without crushing or deforming the hinge flange and 
channel protrusion.

Referring to FIG. 1, reference numeral 1 designates a pickup truck cap 
constructed of the cap frame 2 comprising the longitudinal stringers 3a, 
3b and 3c connected to the end frame member 4 which, as disclosed by the 
cutaway portion, includes the upright portions 4a and top portion 4c 
between which is the arcuate corner portion 4b bent to form an arc which 
is compatible with the shape of the truck cab (not shown). The cap frame 2 
also includes a cross support 4d (FIG. 3) secured at 5 to the portions 4a 
and 4b at the juncture thereof and a side support member 4c (FIG. 3) 
secured to support 4d at 7. Cross support 4d is provided to give rigidity 
to the rearward portion of the cap frame and to provide a support for the 
top horizontal door frame member 10, the cross section of which is more 
specifically disclosed in FIGS. 5A, 6A and 7A. Side support members on 
each side of the cap also give rigidity to frame 4 and are provided to 
support the side frame members 11 and 12 (FIGS. 1 and 3) of the door 
frame. 
Cap 1 also includes the cover 80 extending over frame 4 and also includes 
the molding 81 extending around the edges of cover 80 for hiding the 
seams. 
The door and frame assembly comprising top horiziontal frame member 10 and 
side frame members 11 and 12 are conventional. Frame member 10 is an 
extruded aluminum piece having a configuration as disclosed in FIG. 1A. 
Thus, it has an L-shaped section formed by the upright plate-like leg or 
part 13 and the flat horizontal leg or part 14. 
The L-shaped frame member 10 is mounted on the cross support 4d of cap 
frame 2 with the inner face 13a of the leg or part 13 abutting against the 
outer face of cross support 4d and the inner surface 14a of the leg 14 
abutting against the bottom surface of this cross support 4d. Frame member 
10 is secured to the support 4d by fasteners 15 spaced along the length of 
the frame member 10. Formed integrally on the outer face 13b of the 
upright plate-like part 13 is the hinge flange 16 having a well-known 
complicated configuration which includes the web 16a, the curl 16b and a 
bearing curl 16c. 
Flange 16 a hinge part is shaped to receive a complementary door hinge 
flange 17 extending along the entire length of the top edge of the door 
18. The door thus is pivotally mounted by the telescoping flanges 16 and 
17 and fits between the side frame members 11 having a configuration as 
shown in FIG. 1B. This configuration includes the flanges 19 forming 
channels for receiving a trim strip which hides the fasteners 20 and a 
door stop 21 provided by the flange 21 located on the inside edge of the 
side support member 4e. Flange 21 also provides a means for securing the 
side frame member 11 to the flange 14 by the metal screws 22a and 22b 
which are screwed into the openings 21a and 21b formed in the flange 21 as 
shown in FIG. 3 and FIG. 1B. 
In this prior art structure, the flange or leg 13 is cut at a right angle 
as shown in FIGS. 1 and 3 which creates an interference problem with the 
molding surrounding the door and door frame. FIG. 3 illustrates this 
problem. Assuming that the molding around the door and door frame extends 
along the arcuate line 30, it is necessary that the door frame does not 
extend beyond this line. In order to prevent the corner of frame member 10 
from extending over the line 30 it is necessary that the cross support 4d 
of the cap frame, and accordingly the frame member 10, must be located a 
substantial distance below the top horizontal portion 4c of the cap frame 
4 as shown in FIG. 3. This greatly reduces the height of the door which 
can be fit into the frame, a problem that has existed for years without 
any solution. 
Further, as shown in FIGS. 1 and 3, the straight line square shape of the 
end of the frame member 10 gives an undesirable aesthetic appearance to 
the entire assembly. The industry has endured this undesirable appearance 
for years without any solution. FIGS. 2 and 4 disclose a solution made 
possible by this invention, i.e., cutting the end of the frame member 10 
along an arc which substantially matches the top corners of the cap, such 
cut being along the line 31. Having made this conception, the problem then 
presented is the forming of the arcuate ends at a practical cost without 
deforming the hinge flange 16 and the channel flange 28, it being evident 
that deformation of these flanges would prevent insertion of the door 
flange and the trim strip as previously discussed. 
We have solved this problem by a unique and novel method involving the 
steps as illustrated in FIGS. 5A-C, 6A-C and 7A-C. Referring to these 
figures, it will be seen that FIG. 5A represents the prior art square cut 
end which includes the upright plate-like leg 13 and the flat horizontal 
leg 14. Extending from the top edge of leg 13 is the channel flange 28 
which in cooperation with the flange 27 provides a channel for receiving 
and holding a trim strip (not shown). The flanges 28, 27 and hinge flange 
16 are formed as an integral part of the legs 13 by the extrusion process. 
The first step in our method is to cut the extrusion into lengths as 
required for support of the door, it being understood that the required 
spacing of the side frame members 11 which are attached to the extreme 
ends of the leg 14 of the frame member 10, determines such lengths. Thus, 
initially the length of the frame member 10 before being processed is the 
same as in the prior art construction of FIG. 1. 
The second step is to shear the flanges 16 and 28 as illustrated in FIGS. 
5B, 6B and 7B. Specifically, hinge flange 16 is sheared along the lines 32 
on the plane of the space of surface 13a. It is also sheared in a 
direction designated by the arrow A (FIG. 6B) so as to completely remove 
an end portion of the hinge flange 16. 
The flange 28 is also sheared along the plane of the face of surface 13a 
along the lines 33 and is removed from the leg 13 by cutting the flange in 
the same direction A. This produces the shape as shown in FIGS. 5B, 6B and 
7B, that is, with the flange 16 terminating short of the extreme ends 34 
of the frame member 10, it being evident from FIGS. 5B and 7B that the 
channel flange 28 terminates much shorter than the hinge flange 16. 
As illustrated in FIG. 7B, this leaves the ends of the frame member 10 with 
a flat surface portion 35 free of any protrusions. The extent of this flat 
surface portion 35 can be varied depending upon the amount of the flanges 
16 and 28 removed. 
The next step in the operation or process is cutting through this flat 
portion 35 along the radius line 36 which is chosen to correspond and be 
compatible with the radius of the top corners of the cap. This cut 36 is 
preferably accomplished by a tool and die operation. 
It will be seen by comparing FIGS. 3 and 4 that the shape of the end of 
frame member 10 as illustrated by FIGS. 5C, 6C and 7C accomplishes the 
solution to the problems referred to above. First as compared with FIG. 3, 
the configuration at the ends of the frame member 10 permits the entire 
frame 10 to be moved upwardly thus increasing the opening for the door. 
This in turn permits a larger door and larger space for access into the 
cap. At the same time as illustrated by FIG. 4, the radius 31 can be made 
to match or nearly match the radius of the top corner of the cap. 
FIGS. 8, 9 and 10 sketchedly disclose tool and die apparatus for performing 
the operations as decribed above. This apparatus includes the base 40 
supporting the die block assembly 41 which is constructed to receive both 
a right hand and left hand end of the frame member 10. This is 
accomplished by providing a number of die blocks 42, 43, 44, 45, 46, 47, 
48 and 49. The die blocks 42, 46 and 47 are formed so that when assembled, 
the cavities 50 and 51 have the approximate shape of the hinge flange 16. 
Mounted on top of the die block 42 is the die block 43 shaped at its 
corners to receive channel flanges 28. The two die blocks 44 and 45 are 
shaped to provide a cavity for receiving the leg 14. The die blocks 48 and 
49 are similarly shaped. Base 40 also supports the stop block 80 which 
provides a stop for properly positioning frame member 10 in the assembly 
before the cutting tools are actuated. 
The length of the die blocks are disclosed in FIG. 10. Die block 43 has a 
length l1 which establishes the distance l2 which is the length of the 
flange 28 removed from the surface 13a as shown in FIG. 5B. This distance 
l2 is the spacing between the end of the die block 43 and the stop block 
80 against which the end of the frame member 10 abuts during the cutting 
operation. 
The length of the die blocks 42, 46 and 47 is l3 which establishes the 
length l4 of the hinge flange 16 that is removed from the surface 13a. 
Mounted over the base 40 on the posts 50 and 51 is the header plate 52 
supported on the springs 53 and 54 and also guided by the posts 55 and 56. 
Supported on the header 52 is the tool support 57 on which the cutter 
tools 60 and 70 are mounted. 
Cutter tools 60 and 70 are mounted on the cutter support 57 by the bolts 62 
as disclosed. The positions of these tools will correspond with the 
portions of the flanges 28 and 16 to be removed. Referring specifically to 
the cutter tool 61, it is essentially a flat tool having a cutting edge 
61a inclined at an angle from the front to the rear of the tool assembly 
providing a forward cutting edge 61b that mades the cut 28b (FIG. 5B). The 
cutting edge 61a also makes a cut along the lines 28a. During this entire 
cutting step, the remainder of the flange 28 is backed by the die block 
43. It should be understood that this cutting action is performed 
simultaneously on two ends of separate frame members 10, one being on the 
left hand and the other on the right hand. 
The cutting tools 70 one of which is a right hand and the other a left 
hand, has a configuration as disclosed in FIGS. 8 and 11. The upper end is 
rectangular in shape. The lower end has the nose 71, shown in broken lines 
in FIG. 8, extending behind the die block 43 and portions of block 42 into 
the space between the two flanges 28 and 27. The nose 71 has an inclined 
arcuately shaped cutting edge 72 defined by the edges 72a and 72b. Cutting 
tool 70 operates by first cutting through the flange 16 along the plane 
defined by the two lines 32 (FIG. 5B) and then cutting transversely 
through flange 16 to remove the same and produce the configuration as 
shown in FIG. 5B. It should be understood that the severing and cutting 
action of tools 60 and 70 as described above in relation to the flanges 16 
and 28 is accomplished in one stroke as the cutter tool support 57 is 
forced downwardly. 
As previously described, after the designated portions of the two flanges 
16 and 28 are severed from the surface 13, an unobstructed flat surface 
13a remains for cutting flange 13 along a line represented by the arcuate 
edge 31. This is accomplished at both ends of the frame member 10 by a 
conventional tool and die operation to produce a member as disclosed in 
FIGS. 2 and 4. The two side frame members 11 are then secured to the 
flange 14 of frame member 10 at each end to provide the door frame. The 
door is then mounted on the frame by telescopingly sliding flange 17 of 
door 18 in the flange 16 to produce the door and frame assembly as 
disclosed in FIGS. 2 and 4. This door and frame assembly is shipped to the 
cap manufacturer who mounts the same on the cap frame 4 as described above 
in relation to FIGS. 3, 4, 1A and 1B. 
Although I have described the preferred embodiment of my invention, it 
should be understood that other modifications and embodiments are possible 
within the broader spirit of the invention. Accordingly, it is intended 
that my invention be limited only as set forth in the appended claims.