Hard Cover like, something, aluminum, already

andy

Here's the deal - I bought a soft tonneau - got a real good deal on a brand new snap style (20 bucks off ebay) - looks and works ok, but i would really like to have a hard flush mount cover.

I was thinking about making my own hard cover from plywood and aluminum channel.  I was going to cover the plywood with 1/2 inch upholstery foam, and then wrap it with the soft cover.

I was also going to waterproof the plywood (probably with something like POR 15).

I already have all the materials, so it isn't going to cost me anything.  Any thoughts?

.sounds awesome, post pics of the progress.

.I've got it started - lots of work, but I think it will turn out ok.  I'll take some pics as I go.

.sounds like a good idea just make sure you use god material.. something water proof and stuff to hold up to the sun.. the vinyl they use in boats works great

.
Originally Posted by BlakDakRTsounds like a good idea just make sure you use god material.. something water proof and stuff to hold up to the sun.. the vinyl they use in boats works great

I am actually going to use the black vinyl from the soft cover - the vinyl is good and thick - some of my buddies think I'm nuts, but I think it's gonna work.

.make sure you brace the under side of your plywood, otherwise, it's going to sag and warp.  by the time you brace it, it's going to be pretty heavy!

.
Originally Posted by 70Cuda383make sure you brace the under side of your plywood, otherwise, it's going to sag and warp.  by the time you brace it, it's going to be pretty heavy!

I have a frame built with two side pieces and 4 cross pieces.  I also am running three strips on top of the wood to hold everything tight, and countersinking cap screws so that there will be no bumps when I put the foam on top.

I have helped my buddeis take off their hard fiberglass covers, and I honestly think that it is still going to be around the same weight.  I am not too worried about some weight on the truck though - should help me in the snow.....

.Attachment 33930
Here is a PDF of a drawing of what I am doing, in case anyone is interested.

I will post pics of the real thing when I get some time.

.Ok - I will be assembling this cover some time in the near future (I have pics of progress - will post when I can get them downloaded) -

I was wondering if I should glue the fabric to the foam, or just pull it tight and fasten it around the perimeter on the bottom side of the wood.  Any input would be great.

.i would just fasten it. just my opinion lol

.Wood cut to size and sealer added:
Attachment 34056

Metal strips added to top side - I put on some foil tape to help seal the edges up
Attachment 34055

Foam added
Attachment 34057

Bottom view of complete cover
Attachment 34058

Attached to truck
Attachment 34059

Attachment 34060

I still need to play around with how it sits, but it turned out not bad.  I have weather stripping all the way around and it didn't leak when I turned the hose on it.  I also have new bed rail caps coming because these ones are cut up. (They had to be trimmed to accomodate the clamps of the soft cover frame.)

.looks nice man! i like that

.well crap man that looks pretty darn nice!!

.wow nice, looks like one the covers that mount flush with the bed rails.

.how has it held up so far?