Sponsored

POOR MANS TONNEAU COVER w/ Plywood

DarkStormy

2.5L Hybrid
Well-known member
First Name
William
Joined
Sep 18, 2021
Threads
3
Messages
200
Reaction score
342
Location
Maine
Vehicle(s)
Nissan Frontier
Engine
2.5L Hybrid
I live just north of Los Angeles, the cross winds get very strong hear at times in the mountains etc. I had a trifold with six metal hold downs, the wind got under it and broke the front four leaving the rear in place and the rest draped over the tailgate. I got stopped before it went airborne. Flexible bungee cords are a horrible idea unless you want your plywood cover to fly through someone’s windshield and kill them.
Actually rubber bungees will give and stretch a long way before they fail, I drove flatbed tractor trailers for 6 or so years, and Our tarps were held down with rubber bungees in all weather conditions, the key is to use the right amount of them.
Sponsored

 

Ronaldo

Well-known member
First Name
Ron
Joined
Jun 19, 2021
Threads
4
Messages
210
Reaction score
260
Location
Los Angeles
Vehicle(s)
71 bronco, 67 conv Mustang, 93 RX7 R1
Actually rubber bungees will give and stretch a long way before they fail, I drove flatbed tractor trailers for 6 or so years, and Our tarps were held down with rubber bungees in all weather conditions, the key is to use the right amount of them.
Plywood and tarps are to different things Let’s just say I don’t want to drive beside you
 

KGillies

2.5L Hybrid
Well-known member
Joined
Aug 5, 2021
Threads
13
Messages
207
Reaction score
277
Location
Santa Barbara
Vehicle(s)
Maverick XL Hybrid, Rav4 Prime
Engine
2.5L Hybrid
Truxedo pro X15 roll up tonneau cover can be had for $539.00 I put 1 one my Colorado and love it's super low profile
If anybody else is thinking along this line, you need 1/2" Baltic Birch 5x5 sheet, marine grade preferable. Water seal is worthless - paint it all around (with several layers on the end grain) with a bombproof automotive paint to match the truck. Use U strut channel for the side attachment - you have to slide it in to be safe, and the locking tailgate will secure it. MUCH more secure than a rollup and will last longer. Rollups don't last and don't hold snow.
If you're going to buy one, the Extang Xceed for $850 is a good buy. I ordered one but if they don't get it together bu the time the hybrid arrives, I'll do the above and paint it silver to match the truck. There is also stainless diamond veneer that would look cool but watch for those hand cuts.
DIY is awesome, ignore the naysayers.
 

KGillies

2.5L Hybrid
Well-known member
Joined
Aug 5, 2021
Threads
13
Messages
207
Reaction score
277
Location
Santa Barbara
Vehicle(s)
Maverick XL Hybrid, Rav4 Prime
Engine
2.5L Hybrid
Buying a brand new truck and then trying to “poor mans” something don’t really go together. Don’t buy a brand new vehicle if you can’t afford a tonneau cover.
that's just plain dumb. it's a pickup.
 

Sponsored

KGillies

2.5L Hybrid
Well-known member
Joined
Aug 5, 2021
Threads
13
Messages
207
Reaction score
277
Location
Santa Barbara
Vehicle(s)
Maverick XL Hybrid, Rav4 Prime
Engine
2.5L Hybrid
The below would be easy to build and probably quite secure with right channel metal strips.

https://shedheads.net/wp-content/uploads/2018/11/DIY-640x480.jpg

But as a contractor I'd look at the bare minimum costs of:
2 sheet of xterior plywood/or whatever ($45x2)=$90
6 corner metal brackets = $20
2 (5' channel metal) frame =$40
Various bolts and hardware ($15)
Hinges possibly $20
Paint - xterior, easily for anything decent ($45)
Weather proofing rubber trim $15
Easily $245 = the cheapest possible costs.
Labor Free
Weight 100 pounds

If the only option for a Tonneau was $900 I'd consider a build but not when they're some available in the $290-$400 range with probably far superior weather resistant light weight materials (45 pounds) that have a degree of engineering not to leak and minimum efforts to install and remove.

I'd bet the Tonneau manufacturers will get a kick out of this thread.
nope - 1 sheet Need 5x5 baltic birch ply - no problem. Slide it in U channel, done.
 

KGillies

2.5L Hybrid
Well-known member
Joined
Aug 5, 2021
Threads
13
Messages
207
Reaction score
277
Location
Santa Barbara
Vehicle(s)
Maverick XL Hybrid, Rav4 Prime
Engine
2.5L Hybrid
No one ever said it had to be made from one 4'x8' sheet. If I had to do this today, I'd cut the first piece wide enough to sit on top of and over-lap the bed rails, with a couple of 2"x3" (nominal) cleats underneath, to provide strength and side to side location. The remaining 5 or 6 inches gets cut from a 2nd sheet, or 2 shorter pieces spliced together, again with a cleat underneath. The 60" x 60" sheet idea is a good one, albeit an expensive option. The 2x3 cleats underneath provide a solid area to add eye-hooks or similar to the attach the bungees or straps to. Having a seam is no big deal if you're going the wrap the sheet with vinyl or some kind of waterproof membrane.

I'm on a trip overseas right now, otherwise I'd make a sketch and upload it.

HRG
too complicated - Need 5x5 baltic birch ply - no problem.
 

Hot Runr Guy

2.0L EcoBoost
Well-known member
First Name
Terry
Joined
Apr 27, 2021
Threads
101
Messages
4,262
Reaction score
7,913
Location
West Chicago, IL
Vehicle(s)
2024 Edge SEL, 2024 Lariat Tremor
Engine
2.0L EcoBoost
Clubs
 
Sponsored

Stevospeedo

Banned
Banned
First Name
Steve
Joined
Oct 14, 2021
Threads
3
Messages
101
Reaction score
158
Location
Maine
Vehicle(s)
Lariat AWD FX4 4K Towing 245/65R17 Falken WP A/T3W
Rollups don't last and don't hold snow.
This is false. I have always used Truxedo rollups with velcro sides to keep tension. Never had a problem with snow or ever had one wear out for the life of the truck. Even their cheapest models last and function just fine. Adding more slats or higher quality materials just makes them even better.

I would never put a crappy looking piece of plywood as a bed cover. Plywood warps, is heavy, and not exactly cheap right now. But to each their own. If you want to redneck engineer a ridiculous solution that has already been solved, that is your right as a 'murican truck owner.
 
  • Like
Reactions: HPR

04mach146

Well-known member
First Name
Brad
Joined
Jul 28, 2021
Threads
11
Messages
322
Reaction score
605
Location
Florida
Vehicle(s)
Chevy Tahoe, dodge eco-diesel
I live just north of Los Angeles, the cross winds get very strong hear at times in the mountains etc. I had a trifold with six metal hold downs, the wind got under it and broke the front four leaving the rear in place and the rest draped over the tailgate. I got stopped before it went airborne. Flexible bungee cords are a horrible idea unless you want your plywood cover to fly through someone’s windshield and kill them.
I mean that sucks for you but some of those cheap mass produced trifold that your charged tons for are garbage and fail more than you hear about. But again have seen many homemade yet to see one come off even the ones held down with bungees. If your homemade topper is sealed correctly and the bungee keeps that seal compressed no air can get in to pull it off to begin with.. I will be doing mine similar to the video I posted just because it's more secure from others trying to break in. But would feel comfortable with the bungee setup
 

Ronaldo

Well-known member
First Name
Ron
Joined
Jun 19, 2021
Threads
4
Messages
210
Reaction score
260
Location
Los Angeles
Vehicle(s)
71 bronco, 67 conv Mustang, 93 RX7 R1
I mean that sucks for you but some of those cheap mass produced trifold that your charged tons for are garbage and fail more than you hear about. But again have seen many homemade yet to see one come off even the ones held down with bungees. If your homemade topper is sealed correctly and the bungee keeps that seal compressed no air can get in to pull it off to begin with.. I will be doing mine similar to the video I posted just because it's more secure from others trying to break in. But would feel comfortable with the bungee setup
What, do you sell bungee cords? The early cars used leather belts as hold downs, Jeep uses hard thick rubber hold downs. No engineer at any car company would ever say “ let’s just use bungee cords to hold that down” They would get laughed at and be stripped of their engineer degree.
 

04mach146

Well-known member
First Name
Brad
Joined
Jul 28, 2021
Threads
11
Messages
322
Reaction score
605
Location
Florida
Vehicle(s)
Chevy Tahoe, dodge eco-diesel
What, do you sell bungee cords? The early cars used leather belts as hold downs, Jeep uses hard thick rubber hold downs. No engineer at any car company would ever say “ let’s just use bungee cords to hold that down” They would get laughed at and be stripped of their engineer degree.
No, no stock what so ever and yes you are correct a car company would get laughed at for mass production vehicles getting that. But that's what it's considered a homemade tonneau not everything has to be engineered to death. I realize your from California land of extreme caution I mean heck even water gives u cancer in CA. But for the average joe that isn't an engineer and had literally seen hundreds of sheets of plywood held down by bungees and be fine at highway speeds I will not be taking you opinions that it will fail as facts. Yes someone may build a setup that fails but hey wasn't you the one that said the manufactured one fail so I mean did that engineer get laughed at for a part failing... if you feel unsafe by a bungee being used don't use one simple but to tell someone else not to because your professionally built topper failed is stupid.
 
Last edited:

Decayed

2.0L EcoBoost
Well-known member
First Name
yes
Joined
Oct 18, 2021
Threads
51
Messages
3,358
Reaction score
5,210
Location
Directly above the center of the Earth
Vehicle(s)
a car
Engine
2.0L EcoBoost
I just ordered this one today...
Please keep us posted when you get it. I am very interested in how secure these are. I occasionally have to park in areas that are sketchy AF and security is a big concern.
Sponsored

 
 







Top