Poor man's Tonneau Cover - Replacement

[kach22i]

Replacement for Tonneau Fabric - Coroplast

My button snap fabric tonneau cover shrunk too much to go back on. I even tried soaking it for hours in warm water to expand it, and all I got was a dirty bathtub out of it.

I used a dusty 4'x8' piece of black coroplast which has been sitting in my garage for the last two years (for a project I never did).

$25 for the coroplast (cuts with utility knife for trimming)

$10 or so in screws

$10 for two 3"x48" ABS plastic strips

So for less than $50 I have a removable cover, will need a 1/4" hex driver and a flat-head screw driver to remove it. I suppose I could have used Velcro or snap latches but I was trying to keep the costs down.

This project takes just a couple of hours to do, you don't need your old tonneau cover frame, but I suggest you do reuse it, or at least cut up some angle iron or aluminum angles for some cross members for those of you which get snowfall.

If you can get the ABS strips the full length of the bed do so, I was using scrap and limited in length. You could also use 1/16" x 3" flat stock aluminum or some other material you find at the scarp yard or hardware store.

S10 4x4 Pick Up Photos by kach22i | Photobucket


I suggest weighting the cover so it lies flat when drilling and screwing.

Don't over tighten the hold-down screws.






This is the one detail which did not come out well, like I said use a full length 6-ft or 7-ft strip of something to avoid this kind of thing.


I did not use any foam rubber gasket material, I did not want something easily damaged when I take the cover off, plus this allowed me to use shorter screws.

I made all the holes in the coroplast oversized to allow for expansion and contraction.

I still have to test drive this thing, and will report any testing problems which may show up over time.

I'm just to cheap to spend over $300 right now, this will just have to do.

[peppy]

You are a brave man...I bet these pictures have already been lifted and archived to use against you.

[EarlyPorsche]

Not the best not the worst. Function over form usually makes more sense. You probably could have made the form better. Lets just say your cover fits the sport truck look you have going on. I think it worked out pretty well and you're not $300 deeper into a cover that really wouldn't be THAT MUCH different.

[john70t]

The soft cover may not hold up in cold weather as well.
They're saying heat is the trick: Stretching a soft tonneau cover

[Brando]

I wouldn't drive behind that...

Why not buy one of those hard covers that is supported by struts that locks closed? They can even paint it to match your shade of flat black (or just leave it as gel-coat carbon fiber/fiberglass).

[A930Rocket]

Because they can cost about $1000 IIRC.

I wouldn't drive behind that...



Why not buy one of those hard covers that is supported by struts that locks closed? They can even paint it to match your shade of flat black (or just leave it as gel-coat carbon fiber/fiberglass).

[RANDY P]

Originally Posted by peppy

You are a brave man...I bet these pictures have already been lifted and archived to use against you.

LOL!

I like the fin on the back- even if it's been vandalized by an O sticker.

[Racerbvd]

Originally Posted by A930Rocket

Because they can cost about $1000 IIRC.

Well, he has been saying how much more business he has had since 2008 (course you wouldn't know by the number of photoshop crap he post) he could afford one..
Back when I was in high school, I made one out of plywood, foam, black vinyl, & some 3M spray adhesive & a staple gun, didn't cost much, framed & hinged so I could lift the rear to get to my BMX bikes
I got a lot of compliments on it at the Mini Truck meets & Cruise ins (78 Datsun King Cab). Since I raced BMX & worked in a bicycle shop, I didn't have a lost of extra coin, so I had to do a lot of stuff myself, but cared enough to noit only make it functional, but look good too.

But that truck does have that nascar truck look, kind of a evil look, kinda cool..

[Heel n Toe]

That tonneau cover, in addition to the rear spoiler, the snowplow on the front, and whatever you call that contraption on the roof ought to keep that thing absolutely glued to the road above 100 MPH on long sweepers and offramps.

Seriously, kratch... it looks like something a serial killer would drive.

Don't be surprised if the police ask you to drop that tailgate so they can check for bodies or drugs.

[Tim Hancock]

Lol

[kach22i]

Originally Posted by Heel n Toe

That tonneau cover, in addition to the rear spoiler, the snowplow on the front, and whatever you call that contraption on the roof ought to keep that thing absolutely glued to the road above 100 MPH on long sweepers and offramps.

All the aero modifications combined have greatly increased down-force, and with no loss of mpg (a balancing act).

This is a much safer vehicle to drive in wet weather than it used to be. Next time you get "ice out" conditions, check to see which vehicles are in the ditch, they will mostly be pick-up trucks.................but not me.

I just have to do one more oil change and check the air pressure in the tires and I'm ready for winter.

I suspect that there will be much less deflection from snow sitting on the new cover than there used to be with the fabric cover. This might even save me some time with the old push broom this winter.

When this cover gets worn out, I'd like to try one which is the proper width and hinges up, some Monopan from Canada would be fun to experiment with.

I'm expecting to get 2-3 years out of this, much will depend on the UV resistance of the Coroplast.

About aerodynamics; the fabric cover would deflect some from the redirected air over the roof, and flutter at high speed. The flutter is not good for airflow from what I've read. This more rigid material should perform better than the old fabric despite the extra drag caused by the hex head fasteners.

As a bonus, the old fabric cover serves as a travel sized bikini top for when my Targa 911 is parked. No hot leather seats, bird poop or leaves to worry about now. I just drape the old tonneau cover over the top. I might add some grommets to it so that I can bungee it down on windy days.

[kach22i]

UPDATE:

I did some test driving today, some observations below.

45 mph:
You can really feel the aero down force, I'd say there is just as much at 45 as there was at 50 mph before.

70 mph:
The truck tracks really good, better than before - likes to stay in a straight line (which is good).

80 mph:
More down force than before, just shy of that feeling that you are towing something, feels very secure for a vehicle which sits so high off the ground.

There is still some buffeting and deflection of the material past the last spar - just before the rear spoiler. However it is 1/8th to 1/4th of what it used to be. I can see that a perfectly rigid top for the bed would be an even greater improvement.

I was seven pounds low in tire air pressure, huge improvement in rolling resistance now.

I was so happy with the results, that I went to the self-serve car wash and gave her a bath.

[Brando]

While I applaud your tenacity and desire to make something substantial yourself, I highly recommend taking some fabrication classes or spending to money to get the right hard-cover.I'm just waiting for the next thread about this where those self-tapping screws rip out of the plastic they are threaded through, this cover flaps around, breaks or outright flies off, creating a hazard for anyone behind you. My intent is not to bash you, but a genuine concern for your safety and the safety of any motorist following you.

Originally Posted by kach22i

UPDATE:

I did some test driving today, some observations below.

45 mph:
You can really feel the aero down force, I'd say there is just as much at 45 as there was at 50 mph before.

70 mph:
The truck tracks really good, better than before - likes to stay in a straight line (which is good).

80 mph:
More down force than before, just shy of that feeling that you are towing something, feels very secure for a vehicle which sits so high off the ground.

There is still some buffeting and deflection of the material past the last spar - just before the rear spoiler. However it is 1/8th to 1/4th of what it used to be. I can see that a perfectly rigid top for the bed would be an even greater improvement.

I was seven pounds low in tire air pressure, huge improvement in rolling resistance now.

I was so happy with the results, that I went to the self-serve car wash and gave her a bath.

[kach22i]

Originally Posted by Brando

I'm just waiting for the next thread about this where those self-tapping screws rip out of the plastic they are threaded through..........

I'll be keeping my eye on them, thank you for your concern.

Redundancy is a wonderful thing when it comes to connectors.

[RANDY P]

If the bed is covered with self tapping screws and plastic, doesn't that kind of defeat the purpose of having a bed?

I mean, like how do you move stuff now?

[kach22i]

Originally Posted by RANDY P

If the bed is covered with self tapping screws and plastic, doesn't that kind of defeat the purpose of having a bed?

I mean, like how do you move stuff now?

I don't move a lot of stuff in the winter.

I'll just unscrew it in the summer when I have to.

Based on the hassle the fabric cover was getting back on (hot water soaking required), I should be ahead time wise.

[aigel]

Redneck's Tonneau Cover - Replacement, that is!

I don't get tonneau covers unless you are after a certain look?
Is it to keep snow out of your bed?

G

[kach22i]

Originally Posted by aigel

I don't get tonneau covers unless you are after a certain look?

They save gas, no kidding.

In my case the cover works with the rear spoiler as a package.

[Racerbvd]

Originally Posted by aigel

Redneck's Tonneau Cover - Replacement, that is!

I don't get tonneau covers unless you are after a certain look?
Is it to keep snow out of your bed?

G

They keep people from knowing what is in the bed, I could have my bikes in the bed of my truck, and go out after the races and not worry about my bikes disappearing, plus, my girlfriend could stand on it to watch me win
They are also popular with musicians, the good, locking ones, as the can easily load & unload, and don't have to worry about their gear getting wet on the way to a gig.

[BlueSkyJaunte]

Originally Posted by kach22i

I'll just unscrew it in the summer when I have to.

What has been screwed cannot be unscrewed.