DIY Hard Tonneau Cover

I am going to undertake this project out of necessity. I will try to write it up as best as possible with the why, how, where and links and photos.

Why: I need the security of a cover for when I drive equipment around and prefer to secure in bed vs. back seat. Not so much to keep water out, but it would be nice.

• I am using a 12" wide toolbox and that box makes my bed 48" and so a bit of an oddball.

How: I plan to use 1/2" Aluminum channel with 3/4" legs to frame balck textured ABS panels with a flip back design.

Where: I procured the pieces from various suppliers.

• I sourced the aluminum in 20' bars cut to 5' sections for a total of about $70.
• I sourced the ABS Panels cut into 63" lengths for about $110.
• I sourced the Rubber door trim in 1/2" by 1" x 25' length from Amazon.
• I sourced the locking Tonneau clamps from an online supplier for about $30.

Part 1: Create Panels - (2 hours)

• ABS: QNTY 1 - 6"x 63" ABS 1/4" Black textured panel. This goes closest to the tool box.
• ABS: QNTY 3 - 14"x63" ABS 1/4" Black textured panel. These will be hinged together.
• ALUMINUM: QNTY 8 - 1/2 high x 3/4" leg channel. Drilled with 1/8 bit through each leg x 5 holes. Beveled out with 1/4" bit using an inexpensive drill press.
  
• RIVETS: I used 1/8 diameter by 1/2" grip to secure the ABS sheet inside the aluminum channel.
• Will finish panel tomorrow using cut pieces of aluminum channel.

 

Subd, good luck!​

 

Subbed out of curiosity.

 

Good luck, curious to see how it turns out. I considered building one out of plywood and covering with a heavy waterproof canvas but ended up with an oem tonneau on the truck I wanted.

 

So I added part 1 write up. The trim pieces arrive today so with luck, I will be able to fit it this weekend.

 

Looking good!

 

I like it! I'm curious to see the finished product.

 

Or you can find a good used one for less money? I got a 2 year old BAKFlip FiberMAX for $150. Good luck with the project. It looks good so far

Edit - Read first post again. You're incorporating the tool box in the design? Interesting either way.