Homemade Tonneau... Just for the Winter.

[brandont]

You are building a very close design to what I had thought about. I put the design in CAD, but I already have a Bakflip, so I never went much further. Some notes of mine, however:

I don't know how you planned to keep the cover from lifting off. My idea involved architectural C channel (square, not bevelled) and some nylon industrial rollers, slightly smaller than the internal C channel dimension. When you need to remove, just roll it out the end of the bed. I was also going to make 2 pcs, but then I couldn't decide on how to keep the first panel from rolling if I only removed the tailgate panel.

I then switched to a 1 panel concept, but currently I am thinking about how to make a dual-action hinge. That is, at the cab end, I want the top to lift straight up and swing. I feel this would allow the weatherstripping to compress better against the cab.

If you bond the diamond plate to the frame, I suspect you will be able to put considerable weight on it. You may also want to weld or bond the crossmembers to the end members. I think you may find that you can stand on your cover if you weld or bond it all together.

Lastly, McMaster-Carr has a TON of weatherstripping. I didn't know how you bent your diamond plate. I planned on leaving mine unbent and adding the weatherstripping along the edge.

Hope that helps.

[xridgelinex]

brandont, my first design was similar to yours. I was going to use for the rails 3/4" c-channel and then was going to use 1/2" plywood surrounded by 1/2" c-channel. The panels then would fit nicely into the rails....

...I am bonding and riveting the diamond plate onto the frame.
...I designed the frame so that the each cross member is self supporting on the rails therefore, the joints are not relied on for structural integrity.
...I had the diamond plate bent on 3 sides to surround the frames. This added to the strength of the diamond plate and leaves the 2 halves flush with each other. I had the diamond plate bent at a local machine/metal shop.

I am leaning on using perko removable boat hinges to attach/hinge the 2 sections. I am using link lock clasps on the back half and torza clamps on the tail section.

[BIGGUY]

That seems like alot of work to go through, when you could have bought a Retrak or one of the other covers and installed it ypourself and useing it. And got alot better fit. I mean it took about 2hr's to assemble and install my Retrax.

[xridgelinex]

That seems like alot of work to go through, when you could have bought a Retrak or one of the other covers and installed it ypourself and useing it. And got alot better fit. I mean it took about 2hr's to assemble and install my Retrax.

Hardly any work at all. The entire process really is about one day's worth of work. It's like your doggy deck, why go through all that you did when all you needed to do was throw down some pillows...

All nit picking aside, the most important part of this project or any ones is that we enjoy the challenge, process and the outcome.

[xridgelinex]

Update 7/9

The project is going slow but here are some pics for all of you to drool over... Total cost so far is $394.50. I know it will surpass $400 when complete but my estimate is around $420. Not bad considering half the cover had no problem supporting all 350 lbs of me ...

Cost:
1) Rails: Torza HH Premier $68 with shipping
2) 2 New Clamps from Torza $19.50
3) Aluminum Diamond Plate welded and bent $160
4) Aluminum tube 1.5" x 3/4", & 3/4" x 3/4" (1/8" walls) $134
5) 1.5" "L's", Self tap screws $13.00

[xridgelinex]

And some more pics...

[xridgelinex]

Last ones for now...

[k757]

Originally Posted by xridgelinex

Update 7/9[/font][/color][/b]

The project is going slow but here are some pics for all of you to drool over... Total cost so far is $394.50. I know it will surpass $400 when complete but my estimate is around $420. Not bad considering half the cover had no problem supporting all 350 lbs of me

VERY NICE! You have far outdone the current covers on the market.

Do you have a locking mechanism for it? ... not that it will fly off but so it doesn't walk away.

[shovelhd]

Stunningly beautiful. Outstanding job.

[xridgelinex]

VERY NICE! You have far outdone the current covers on the market.

Do you have a locking mechanism for it? ... not that it will fly off but so it doesn't walk away.

Thank you for the kind words.... As for the locking, the front section clamps are a locking variety. The tailgate section torza clamps allow for locking of the clamp handles. This will keep the honest people honest.

I thought about the dishonest and the ways to circumvent the entire system including the tonneau rails... but hey if they want the tonneau cover that bad that's a one off for the RL, there is an extra locking mechanism surprise that will defiantly leave a mark, or should I say "stain"...