Homebuilt Bed Cover / Tonneau Cover

[chris_kucia]

I have a soft tonneau cover (Truck Tek?).

 

Its OK. I'd really like a hard cover, but they're a little spendy for my old truck.

 

Been toying with it in my head for a few days and came up with an idea.

 

 

Thought I'd get some of that pink rigid foam insulation. Its not structural, but its pretty strong. According to the owens-corning site, its essentially waterproof and its cheap and light. I think it would be strong enough to hold snow, which is all I really need.

 

I thought I'd use one piece that was wider than the bed to sit on top, straddling the rails.

 

Onto the bottom, glue a second piece that would fit between the rails.

 

Cover with aluminum roof flashing for strength, durability, and a good surface for paint.

 

I'd want three or maybe four panels. I was thinking I could use some long metal rods that slid through them to hold them together as a unit. Maybe sliding gate bolts underneath to retain them along the sides.

 

Just sorta thinking out loud right now. Still need to figure out how the panels would interlock to keep water out.

 

 

I'd welcome any suggestions/ideas anyone has before I get too far along.

 

Maybe use something like angle iron or oak strips to add some rigidity before covering with the flashing?

[2000DV4.8]

Sounds like it could work, but seems like too much effort for something that might not last.

 

If you want a hard cover but don't want to spend a ton, I'd look around for a used one.

[GMCSierraSLE1500]

A guy who worked where I worked had a Ford Explorer Sport Trac and he make a hard tonneau cover out of wood, I believe plywood is what it was I dont recall as I dont work there anymore so I don't see it, it's the exact same stuff they use for roofing before the shingles and such are placed, he cut it to match the length of his bed, cut curves for the end corners so it looked like it was meant for the bed and then he painted it to match his truck, personally it looked like crap but to each his own, I mean if it was me I would go out and buy a cover not make one unless the idea is a good one(like chris_kucia idea) but this guys idea wasnt that good of an idea as it was pretty bad looking.

[Gray Ghost]

That is funny you mentioned making your own tonneu cover. While working two days ago I saw a Ford Ranger with a sheet of 3/4" plywood as the tonneu cover, it had hinges near the cab, and a pad lock style mechanism near the tailgate handle....Hopefully the plywood was treated well....I wonder if he gets water inside....WOW..... He could have atleast painted the plywood to match the truck..

[Rosedog]

Have thought about it many times...

 

All I would need is some:

 

*Flat bars

*Plywood

*Fiberglass

*Struts

*Carpet

*Paint

*Power Tools

*TIME

[chris_kucia]

I originally thought about plywood, but its kind of heavy, especially if you get it think enough so it doesn't sag over time.

 

Then you have to cover it with something to protect it.

 

I like using the foam as a core because its very easy to shape, and its lightweight.

 

Thought about covering it with fiberglass resin, but then I hit on the idea of the aluminum flashing, which should be plenty durable, especially since the foam resists water as well.

 

 

I sorta wonder how much work it would be. I think making the actual panels up and covering them would be pretty quick. Its finding a way to attach them securely and seal them that will probably take up a lot of the time.

 

 

I have been keeping my eyes open for used covers, but in my area, they just don't seem to come up very often.

[PhilB]

Hey Chris,

 

I don't know where you are located, but I did a search on Craigslist and found a fiberglass cover up in Cicero, IL. It's in need of a paint job but for $120, not a bad deal. http://chicago.craigslist.org/chc/pts/754355810.html

 

I used a program called CLSearchPro that will search the cities with CL for whatever keywords you want.

 

Phil

[18702GMT900]

That is funny you mentioned making your own tonneu cover. While working two days ago I saw a Ford Ranger with a sheet of 3/4" plywood as the tonneu cover, it had hinges near the cab, and a pad lock style mechanism near the tailgate handle....Hopefully the plywood was treated well....I wonder if he gets water inside....WOW..... He could have atleast painted the plywood to match the truck..

 

That's funny I've seen plenty of those where I live, what's funnier is seeing someone rigged up a big cargo box out of plywood and use their pickup live a cargo delivery truck

[silverbullet2005]

sounds a little redneckish to me but if it works for ya then by all means get r done!!!

[chris_kucia]

Hey Chris,

 

I don't know where you are located, but I did a search on Craigslist and found a fiberglass cover up in Cicero, IL. It's in need of a paint job but for $120, not a bad deal. http://chicago.craigslist.org/chc/pts/754355810.html

 

I used a program called CLSearchPro that will search the cities with CL for whatever keywords you want.

 

Phil

 

 

I'm in OH. IL is a little far for a cover, but that's a good price.

 

Thanks for the info on that program - I can really make use of that.

[Gray Ghost]

Ive seen it all now... a truck with a custom cut piece of privacy fencing covering the back window for protection from the cargo....then I saw one that looked exactly like someones headboard to their bed with the posts still on it going up each side of the cab...whew....Maybe when I work dayworks Ill take some pics for the ole forum...whew

[chris_kucia]

Laptop crashed while I was posting. Forgot what I was going to say. Can't seem to figure out how to delete a post.

[BigJayDogg3]

Laptop crashed while I was posting. Forgot what I was going to say. Can't seem to figure out how to delete a post.

 

That's because you can't. Only mods. and/or admin. can.

[silverad03]

I would be leery of using the aluminum flashing for a covering. That stuff is so thin that over time it will accumulate all kinds of dents and dings and probably look bad pretty quick. Fiberglas resin would be better if you can do it for the right price.