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  #1  
Old 11-18-2012, 08:59 AM
mxlance mxlance is offline
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Default diy tonneau cover

hello,
i am new here this is my second post.
after pricing new tonneau covers i decided to make one myself.
i made it for under $100. works well so far. nothing fancy, just to keep the rain out. still it does not look to bad.

if any one would like a detailed step by step of how i did it, i am happy to post more info.

this looks like a great forum.

thanks
Attached Images
File Type: jpg truck tonneau cover B.jpg (37.0 KB, 324 views)
File Type: jpg truck tonneau cover A.jpg (37.3 KB, 288 views)
File Type: jpg truck tonneau cover 4.jpg (31.7 KB, 279 views)
File Type: jpg truck tonneau cover1.jpg (39.4 KB, 272 views)
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2003 XLT Longbed 3.0
Homemade Tonneau and cargo holders
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  #2  
Old 11-18-2012, 09:04 AM
OhioMike OhioMike is offline
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Default Re: diy tonneau cover

Welcome. Another ohioan, and not too far away from me. I live in Middleburg Hts. actually. Nice cover.
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  #3  
Old 11-18-2012, 09:07 AM
Nothing but Fords Nothing but Fords is offline
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Default Re: diy tonneau cover

The cover looks great,but I'm not a fan of the Velcro ones.Back in 88 when I got my 1st Ranger that all they had.good luck hope it last a long time for ya.
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Last edited by Nothing but Fords; 11-18-2012 at 12:37 PM.
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  #4  
Old 11-18-2012, 09:16 AM
Devin-20 Devin-20 is offline
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Default

Not to bad for $100.
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Quote:
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  #5  
Old 11-18-2012, 09:28 AM
sgtsandman sgtsandman is offline
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Default Re: diy tonneau cover

I like it!
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2011 Ranger XLT, 4X4, 4 door Super Cab. 4.0L, 5 Speed M50D-R1HD, 3.73:1, 8.8" open differential, Jason Pace cap
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  #6  
Old 11-18-2012, 06:11 PM
cam615 cam615 is offline
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Looks great nice work!
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  #7  
Old 11-18-2012, 06:32 PM
02BLUEdge 02BLUEdge is offline
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Default Re: diy tonneau cover

Looks great! It is a great feeling to finish a project, step back, and say I did that myself. Be proud friend, you deserve it.
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  #8  
Old 11-18-2012, 07:59 PM
JackOTrades JackOTrades is offline
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Default Re: diy tonneau cover

That looks great! I would be interested in a step by step on how you did it, since I am looking for a tonneau cover myself.
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2003 Ford Ranger Supercab Edge 4.0 4X4
Current Updates: Remote start/keyless entry, Kenwood KDC-BT952HD w/XM radio, fog light mod, cargo lights, mustang dome, gentex mirror with compass and temp, Tonneau Cover
Planned Updates: Better Speakers, Custom Behind the Seats Storage Box, Body Lift, Bigger Tires, Front Hitch Mount, expo roof rack
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  #9  
Old 11-18-2012, 08:20 PM
greenmachine2000 greenmachine2000 is offline
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Default Re: diy tonneau cover

tell me how!!
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  #10  
Old 11-19-2012, 06:46 AM
mxlance mxlance is offline
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Default Re: diy tonneau cover

thanks for the feed back.
i am putting together a step by step how to right now. it will most likely be some time after thanksgiving day before i can post it. i do the cooking here and have a lot to do. so check back at the end of the week for the info. i have not checked yet, but can we upload pdf. files? i was thinking that would be a good way to post it if we can.

thanks again for the good words
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2003 XLT Longbed 3.0
Homemade Tonneau and cargo holders
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  #11  
Old 11-19-2012, 07:08 AM
merlin215 merlin215 is offline
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Default Re: diy tonneau cover

Nice job !!!
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  #12  
Old 11-19-2012, 10:32 AM
Skylark65 Skylark65 is offline
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Default Re: diy tonneau cover

can you post a close up pic of the clamps you used to secure the aluminum side rails? and where did you get them?
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  #13  
Old 11-19-2012, 11:59 AM
LordNikon LordNikon is offline
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Default

That is a great job!!!! What material did you used for the cover????

Sent from my iPhone 4 using FRF App
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  #14  
Old 11-21-2012, 11:16 AM
mxlance mxlance is offline
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Default Re: diy tonneau cover

DIY Tonneau Cover (step by step)

items used:
•3 yards of marine vinyl (from joann fabrics) it was 55 -1/4" wide $27.00 (on sale)
•2-1/16x1x8' aluminum angled 26.75
•hook and loop strips (about 50') 20.00
•vinyl glue (i used lactate and about 6 tubes) 23.00
•e6000 glue 4.50
•Black silicone Caulk 4.50
•small screws (i used coated household gutter and downspout screws) 3.00
•6 -1/4" Beam Clamps (found in the electoral department of Lowes) 12.00
• kitchen plastic wrap 2.75

total= $123.50
shower curtain rods + $8.00



*Note about velcro/hook and loop. the glue on them sucks. it does not mater what you buy, it will not sick for long to anything used out side. it must be glued. so don't wast your moony on the expensive stuff. i found a generic hook and loop at a craft store for $1.97 for eight feet. the velcro stuff was $14.


step 1:
cut aluminum to bed rail length with gate up.

step 2:
glue hook strip* on top side of aluminum bar. i used the e6000 but i think PL600 would be a better choice.
clamp the hook strips down using a 1x2x8 to sandwich it evenly. let set for one hour. unclamp and let dry 24+ hours.

step 3:
run a bead of black caulk along the side of the aluminum. place on bed rail and position just above the rail so water will drain away from the cover (i hope). Hold in place using temporary clamps. next apply the beam clamps so that the bolts are in back. this is not easy to do. i think that i will get some shorter bolts that will make it easier to tighten down.

step 4:
pretrial 3 small holes (one at each end and one center) on each aluminum rail. screw the hook strip down tight.
this is to hold it more securely place. the weak points are at the ends.

step 5:
glue and screw hook strips on the gate edge and the cab end of the bed. I have a bed liner the is well used so i just glued and screwed directly to the bed liner. if you have a good bed liner,
i would suggest using a flat aluminum bar and gluing to that instead.

Now the cover!

step 6:
trim the vinyl to size and straight. the vinyl i had was raged on one side which required trimming.
i folded on end over 2" and clued in place. i used kitchen plastic wrap top and bottom and weighted it down evenly across the glued fold. this gave me a sharp crease. the kitchen plastic wrap prevented the glue from sticking to the table and the weights i used. (cans of tomatoes and bags of sugar).

step 7:
measure the length from top of the cab/bed rail to the gate top.
i allowed for 1/2" at each end and marked the total on the vinyl.
repeat as in step 6 only folding all the excess vinyl over and gluing it down. this way when the tonneau is rolled up it is this piece that is visible. (see uploaded drawing 7)

step 8:
glue 2 loop strips side by side on all 4 sides as close to the the left right edges as possible as well as at the cab and gate ends inset about 1 inch each (see drawing 8). be sure to clamp or weight them down for an hour or so till glue sets.

step 9:
that is it!
one last item though.
i found that it needed some support at speed. so i used 2 cheep shower curtain rods positioned across the bed.
this has worked well so far.

i also user 2 more curtain rods inside the bed to hold plastic crates at the cab and gate ends.

i hope this makes sense and covered everything clearly.
Attached Images
File Type: jpg step 7 drawing.jpg (47.0 KB, 68 views)
File Type: jpg step 8 drawing.jpg (53.8 KB, 52 views)
File Type: jpg beam clamp.jpg (5.3 KB, 215 views)
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2003 XLT Longbed 3.0
Homemade Tonneau and cargo holders

Last edited by mxlance; 11-21-2012 at 11:18 AM.
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  #15  
Old 11-22-2012, 04:10 PM
2tonefx4 2tonefx4 is offline
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Default Re: diy tonneau cover

Impressive! I might have to do some sort of variation of this. The thought of making my own never crossed my mind. I have a light bar on my truck, so a conventional cover won't work with my truck...
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