YOT 3,743 Posted June 5, 2012 Report Share Posted June 5, 2012 I've wanted a tonneau cover for my truck since I bought it. The cheapest hard cover I could find searching the webs is about $1400 after color match painting. Not satisfied with that, I went and got some 1"x2" tube steel, welded up a frame, covered it with 1/2" solid core plywood, painted it inside and out with 3 coats of enamel then covered the outside with 3 coats of Herculiner. It cost me about $230 including the hinges and seals. I'm pretty happy with the way it came out. Now I need a tailgate lock and it'll be set! 4 Quote Link to post Share on other sites
KennyFSU 249 Posted June 5, 2012 Report Share Posted June 5, 2012 Wow great job, looks very professional and clean. DIY all the way! Have you done a wind tunnel test? Aka 80 mph down the interstate lol. 1 Quote Link to post Share on other sites
YOT 3,743 Posted June 5, 2012 Author Report Share Posted June 5, 2012 (edited) Thanks, Kenny. Nope, only 65. I'm old and slow now. LOL. I have alot of faith it's not going anywhere. Edited June 5, 2012 by Yeoldetool Quote Link to post Share on other sites
haugpatr 972 Posted June 5, 2012 Report Share Posted June 5, 2012 That looks real professional to me. Nice work! 1 Quote Link to post Share on other sites
MT Predator 2,294 Posted June 5, 2012 Report Share Posted June 5, 2012 Looks great! 1 Quote Link to post Share on other sites
NM0 586 Posted June 5, 2012 Report Share Posted June 5, 2012 Good job. Looks clean and professional. 1 Quote Link to post Share on other sites
timy 1,185 Posted June 5, 2012 Report Share Posted June 5, 2012 Excellent work. It seems old tools are still some the best. 1 Quote Link to post Share on other sites
GeorgiaPD 408 Posted June 5, 2012 Report Share Posted June 5, 2012 Very nice. I would not have guessed that it was made from wood. 1 Quote Link to post Share on other sites
liberty -r- death 1,445 Posted June 5, 2012 Report Share Posted June 5, 2012 Very nice work. 1 Quote Link to post Share on other sites
kiddykane 28 Posted June 5, 2012 Report Share Posted June 5, 2012 Very nice 1 Quote Link to post Share on other sites
YOT 3,743 Posted June 5, 2012 Author Report Share Posted June 5, 2012 Thanks guys. The Herculiner is easy to work with and gives a great finish. Make sure you glove up and wear long sleeves, though. It's tough to get off it it gets on you. I spliced the plywood with a biscuit joiner and put the splice over a cross piece. The plywood is glued to the steel frame with gorilla glue and screwed every 6 inches with 1/2" X 10 sheet metal screws. Drilling all the pilot holes in the steel, then drilling 1/2" access holes in the bottom side for the screwdriver took the longest, but was worth doing it that way for the good surface on the top side. It's hinged with three 4" hinges gorilla glued to the plywood and lagged into the truck box rail and ratchet strapped from the interior box tie downs to the steel frame itself. It's sealed with two rows if 1/4" x 3/8" self-adhesive hollow "D" foam weather strip. It weighs about 65 lbs. It's strong enough that my wife and I were on top of it to see the view. Quote Link to post Share on other sites
Dad2142Dad 6,559 Posted June 5, 2012 Report Share Posted June 5, 2012 That's great 1 Quote Link to post Share on other sites
Sumsky 115 Posted June 5, 2012 Report Share Posted June 5, 2012 Fantastic job ! 1 Quote Link to post Share on other sites
unclejake 428 Posted June 6, 2012 Report Share Posted June 6, 2012 Looks like you might have a new profession!! Nice work!!! 1 Quote Link to post Share on other sites
Potus2000 7 Posted June 6, 2012 Report Share Posted June 6, 2012 Thanks for the pics. This is a really clean look! 1 Quote Link to post Share on other sites
22_Shooter 1,560 Posted June 7, 2012 Report Share Posted June 7, 2012 Nice and clean. Looks professional for sure. 1 Quote Link to post Share on other sites
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