Up next “Let It Breath!” Published on September 09, 2025 Author John Mata Jr. Photo Credit JOHN MATA JR. Share article Facebook 0 Twitter 0 Mail 0 Installing SmartCap’s Modular Truck Cap on a Third-Gen Tacoma Installing SmartCap’s Modular Truck Cap System on a Third-Gen Tacoma Camper shells, toppers, caps, or covers—the terms are used interchangeably. Call them what you will, but one thing is certain— there’s no shortage of these truck bed accessories on the market. After a bit of research, however, it became clear that not all bed covers are built the same. Fiberglass truck bed shells have been a staple in the scene for decades but as trends change, manufacturers do what they can to stay on the cusp of evolving consumer demands. Enter SmartCap—a company with its design and manufacturing center located in the wilderness of Durban, South Africa. SmartCap created the world’s first stainless steel modular truck cap system that is a true product of its environment. This cap was designed and tested in harsh outdoor conditions to withstand abuse from the elements and daily use, and can now be shipped to your door and assembled at home! Here is how everything from SmartCap arrived straight off the freight delivery truck. The large box contained the EVO Sport cap, the box to the right held the pre-assembled Drop Rack, and the small box up front contained the Half-Bin cargo unit. The SmartCap system is available in three different packages— the EVOc Commercial for rigorous daily work use, the EVOa Adventure which features double-walled solid gullwing side doors, and the EVO Sport, which is what I selected to install on my 2022 Toyota Tacoma. The EVO Sport features tinted glass gullwing side doors that will enhance driving in town as well as on extended road trips. Even though the SmartCap is only available in three distinct models, there are many optional accessories that can be added to customize each one. The EVO Sport cap creates so much storage space underneath, but adding SmartCap’s Drop Rack platform system will provide even more storage capabilities on top of the cap, so I opted to run with it as well. To help organize onboard cargo, SmartCap suggested its Half-Bin storage system, which fits inside the gullwing window. it goes in easily when needed, and is quickly removable when it’s not. SmartCap utilizes two distinctive taglines to describe its product. “Built Like a Truck” addresses its automotive-grade steel construction as compared to competing fiberglass options that can potentially warp over time. “This Ain’t Your Grandpa’s Truck Cap” is the other line that rings true because the SmartCap is so much more advanced and durable than the lightweight bed shell gramps had on his pickup. Honestly, the initial read through of SmartCap’s website is enough to seal the deal. Its caps are weather-proof, feature a positive air vent to keep dust out, and can hold up to 330 pounds while in motion and up to an impressive 770 pounds when parked. This advantage totally changes the game in regards to adding storage cases or even a rooftop tent in the future. Subscribe to our weekly newsletter Once the EVO Sport box was opened, it was clear this install would be less painful than we had imagined. Each of the five panels were separately wrapped and packaged with care. The possibilities for the SmartCap are seemingly endless, but for now, I first wanted to focus on assembling and installing the EVO Sport and Drop Rack platform onto the back of the Tacoma’s 5-ft. bed. The EVO shell is a five-panel system that is designed to be put together with common hand tools, although a torque wrench and rivet gun were both required as well. Since the assembly process was advertised as being rather straightforward, I recruited my dad, John Sr., to lend a hand. In a matter of two days in the backyard, we had the SmartCap and Drop Rack assembled, mounted, and ready for action. Follow along to see the process from start to finish! Before pulling any of the panels out, we couldn’t help but notice the fitment kit box, which prompted us to open first. Its contents included all hardware and accessories required to complete the install, but more importantly, a brochure that directed us to scan a QR code to fill out the registration form before diving into the step-by-step instruction manual. The QR code led us to SmartCap’s incredibly helpful owner’s hub that informed us of the exact tools we would need before getting started. There are also sections on maintenance to help maximize the life and function of the components over the long haul. The first step called for the large box to be fully unpacked so the panels could be inspected for potential damage that could’ve happened during transit. Everything looked perfect, so we moved onto the next part, which was to disassemble the box to use as a workstation on the floor. Next, the center roof panel was laid flat, and two side panels were attached to it utilizing the included hardware. Using a torque wrench, the bolts were fastened down to 3.7-foot pounds. We could now attach one side panel, the front flange, the opposite side panel, and finally the rear flange—in that exact order. This process was easy, but we made sure to take our time. The hardware for all four panels wasn’t torqued down to spec until everything was fully assembled. Just like the first time we used the torque wrench, all remaining bolts were fastened to 3.7-foot pounds. The next step was grabbing the included weather strip, and finding the two built-in clips on the underside of the rear flange (one on each side). These are used to attach the ends of the strip to. The strip is self-adhesive on the bottom to keep it in place, but we did use glue on the corners to keep the strip right where we wanted. The corners were then clamped down, and the glue was left to dry overnight. The next morning, we removed all the clamps holding the weather strip in place and flipped the SmartCap over so we could start installing the Drop Rack platform. Notice the built-in rail system, which makes the EVO cap easily adaptable to all types of accessories right out of the box! The Drop Rack system arrives pre-assembled and ready for installation, which is a huge bonus. For this application, however, we did have to remove all four pre-installed mounts by drilling the two rivets out and unfastening the center bolt. The mounting holes were too wide to properly align to the rails on top of the EVO cap. (When you place your order, double check with SmartCap to see if this step will even be necessary for your actual truck model.) To alleviate this issue, SmartCap sent four replacement adapter mounts that installed into the same position as the previous mounts. The adapters had to be riveted in and locked down using the same center bolt. Once all four adapter mounts were secured, we moved the Drop Rack onto the EVO cap and checked that all mounting holes aligned with the rack—perfect fit! Once all mounts were rightly positioned, they were then snugly tightened down. The SmartCap and Drop Rack were now fully assembled and ready for the next few remaining install steps. Lookin’ good so far, right? Before the cap could be lifted onto the Tacoma, the instructions prompted us where to install these blocks along the inner rails using the peel-and-stick adhesive on the back side. To access the underside, we simply tilted the cab on its back panel. Next, the cap’s pre-installed harness for the brake light was disconnected. The driver side taillight was removed, and SmartCap’s wiring harness was routed through the bed by accessing a gap underneath the factory bed rail cap. The center bulb socket was removed from the taillight, and the included T-harness was simply clipped into place to give the SmartCap’s brake light the juice it needs to function properly. The wiring was carefully tucked away, and the taillight housing was then buttoned back up. Luckily for us, a few family members dropped by to visit at the perfect time. We now had the extra muscle to lift the roughly 288-pound package. The SmartCap alone weighs in at 218 pounds and the Drop Rack adds another 70 to that, so be nice to your friends and plan accordingly. Per SmartCap’s instructions, we avoided sliding the cap back once it was on top of the bed rails to avoid disturbing the weather strip. The cap was set down and lifted to move back as needed. After checking to make sure the cap was sitting right where we wanted it, pops hopped into the bed and secured the six two-piece clamps (three per side) that attach the cap to the bed. The lower clamp arms slide into the inner bed rail and a long bolt is fed through and torqued to spec into the upper clamp arm. . We installed SmartCap’s Half-Bin storage system last. While there is a Full-Bin option also available that takes up the entirety of gullwing opening, we chose the half-sized version to maintain quick access into the bed. The bin only took 15 minutes to install, and it removes even quicker when it’s not needed. The only thing left was to reconnect the wiring harness to the cap’s brake plug. Overall, the assembly and installation of SmartCap’s EVO Sport and Drop Rack systems was an enjoyable process. The only tricky part was dealing with the mounts on the Drop Rack, but the adapter kit came with new rivets, so all we needed was a simple rivet gun to put them in. The rest of the install was made easy by following SmartCap’s well-documented instruction manual. Assembling the cap really was easy enough to handle at home. I’d suggest having two people on hand to handle the assembly process and 3-4 strong individuals to help lift the cap onto the bed of your truck. SmartCap’s gullwing doors are great features. They allow for easy access into the bed and offer plenty of fresh air while relaxing in the bed after a long day. The Drop Rack is a unique platform-style rack system that smoothly articulates downward thanks to its dual gas struts. Loading and unloading cargo on the driver side is fun and convenient. When finished, the rack simply pushes back up and locks into place. The SmartCap features dual locks on all three doors, sliding port windows on both sides, as well as the front panel to create an opening into the cab. The bright LED light strip at the rear is a nice feature to have as well. While some fiberglass bed caps can make pickups look like an SUV from the side, SmartCap has designed its cap to let trucks still look like trucks. The front panel of the SmartCap has a clear window to allow illumination from the factory third brake light to shine through. This comes in handy when accessing the bed at night.
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