Chevy Colorado & GMC Canyon banner

1 Piece Homemade Tonneau Cover

21K views 24 replies 12 participants last post by  killbucket 
#1 ·
I'm a new member to the site but have been browsing since I bought my coly in March '07. I've gotten a lot of great info and questions answered through here so I thought I would share my recent project with everyone.

To start, I use to have a '00 Silverado Z71 that had a Checkmate FX flush mount tonneau cover with the gas shocks (already had it when I bought it). I absolutely loved that tonneau cover, not only did it look good I was able to avg 22 mpg with a 5.3 V8.

I sold it when I decided to go to college since I had to drive 75 miles a day round trip for 2 years and decided that I couldn't afford gas along with the payments so I bought a 03 Grand Prix GT.

So now that I finally got a truck again I decided that I wanted a tonneau cover but there was no way that I could afford to get a Checkmate cover and I'm not too big on the soft vinyl covers since I've had bad luck with them in the past. So after months of searching on the Internet for homemade Tonneau covers, all I've found was people who have made them out of plywood and in multiple pieces.

Since I work in a sign shop I have access to all sorts of aluminum extrusion and aluminum sheets.

I have built a aluminum 1 piece tonneau cover. Since I have a Crew Cab I was able to get a 5'x5' piece of aluminum and some aluminum sign extrusion to use as the frame to lay on the top rails of the bed. After about a month of planing and a day to build it I finally put the it on the truck tonight and honestly in my opinion looks good considering that its home made and only cost me about $110.00.

All I have left to do is paint it but I doubt that will happen until spring unless we get one last weekend of 60's or 70's here in Kansas

I just thought I would share my DIY project I've been working on with everyone. and would like to get your feedback.

I will try to post some pics tomorrow.
 
See less See more
#3 ·
Hurry up and get those pic's up you have got my curiosity goin :) :clueless :)
 
#6 ·
Thanks, the entire thing weighs about 20-25 lbs maybe. Its kinda tricky to get on by yourself without scratching the truck but its light enough that the wife can actually help me take it on and off. so I'm happy with it, plus it only cost me $110.00
 
#8 ·
Wolf,
I'll be painting it a flat black when the weather gets a little warmer, It seals really well if you pull the straps down tight, as far as does it leak, I don't know I'll find out when it rains, I may have to do some more looking for a good adhesive back weather strip thats not the foam stuff I just have the cheap small "D" weather striping that I found at walmart, and I have to figure out how to get a seal at the tailgate since I have the tailgate protector on it raises it up about a half inch towards the back but its a working progress.

I'm thinking about getting a kit that I will be able to lock the tailgate which is all you need since you I have the straps buckled you can't lift it up any. as for making it hinge I was actually thinking about it but I couldn't find any hinges that would work for easy removal, and putting gas shocks to raise it would be alright, but pulling it back down you would probably bend the crap out of it since it is aluminum and not very sturdy when by itself.

let me know if you have any other questions.
 
#9 ·
Wow....looks perfect man. Good job!!

After looking at this and burns cover, Im contemplating trying to make my own. Thats if i dont find a used one for cheap.

The Wolf!! You've got a PM!
 
#16 ·
Huurb, I don't know if it will hold up a ton of weight but I think is should hold snow alright. you could probably put some cross beams which I might do sometime.

I'm thinking about painting it this weekend, if the wife doesn't have and home projects that she wants done, so if I do get it done, I will put some finished pics up.
 
#17 ·
I think your idea of cross beams will help and probably reduce any flex caused by the airstream. Nice work!
 
#18 ·
#19 ·
Wow man...it looks great! :D
 
#22 ·
l2mb
you could make one for an extended cab since all the beds for the colorado/canyon are the same width, I think 57" wide and the aluminum I used I was able to get in a 5'x5' piece and the aluminum rails I use is called h-molding made by sign comp come in 24' lengths and cut them down to the size I needed. As far as cost just check with a sign shop and see how much they would charge. for the material.
 
#24 ·
nope, I don't have any "drumming" as you put it, I have it strapped down pretty well so when I do hit a big bump I just hear the bed itself rattle a little bit, but nothing serious.

just a little update, was up in KC last weekend and it rained overnight and nothing in the bed was wet so thats a positive, and Huurb asked if it would hold up with snow and ice on top of it... well here in Kansas we just got dumped with about 6 inches of wet snow and it handled it pretty good, I had a little bit of the bow in the center but that was expected so I think this spring I'm going to put the cross beams in and hopefully make it more solid.

and also, I've actually increased my mpg by 2mpg I was getting about 19 mpg now its about 21mpg. I drive the truck from home to work and hardly take it long distances. So I drive about 16 miles round trip to work and back and then trips back into town 3 or 4 times a week so I can go on a take of gas now for about 2.5 weeks before I fill up and I always fill up when it gets down to a 1/4 tank.

later.

adam
 
#25 ·
Thanks for the numbers. I will cite them when I'm justifying the materials purchase.


What I'm planning. This will have multiple surface panels, made to a standard outline for interchangability. Material will be ABS, 6mm thick. Poron seals will keep everything dry. The finished item is a demo unit for my airsoft gun activities. Two M2HB's will be mounted side-by side on the lift assembly. A reworked cordless drill will actuate the elevation, and the guns will have drop-in power units.
The top deck will be designed pebble-grain up, and the panel breaks will all be zig-zagged "stealth" style. I plan to leave it black, no paint, to pick up the black body trim.

I can only hope mine is half as clean looking as yours, tho. Nice job there.
 
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top