Another DIY tonneau cover

[CUZICAN]

Like others, I have been disappointed in the available options for tonneau covers, so I finally took it upon myself to make my own. It is made of 5/8 plywood, some square aluminum stock on the underside for rigidity, a little body filler, wrapped in black marine grade vinyl, and held in place by the factory hardtop bolts. Hopefully it'll keep things from walking off when I have the top off.

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[Tricky Mike]

Excellent execution.

 

[WheresMyBronco]

Very clean, well done.

 

[kahunabob]

Like others, I have been disappointed in the available options for tonneau covers, so I finally took it upon myself to make my own. It is made of 5/8 plywood, some square aluminum stock on the underside for rigidity, a little body filler, wrapped in black marine grade vinyl, and held in place by the factory hardtop bolts. Hopefully it'll keep things from walking off when I have the top off.

This is great! I do not know why one of the vendors does not make a plastic/light weight version of this.

 

[Bad_Bronco]

Nice work !!! Can I make a suggestion for easy access, you may want to put a piano hinge on the rear part so that you can lift it up like a lid for more access, and if you have a taller item that you are transporting.

 

[Bigred86]

Wow really nice work!

 

[CUZICAN]

This is great! I do not know why one of the vendors does not make a plastic/light weight version of this.

I thought this would be a perfect application of the style of ABS bedcovers that undercover makes. It would be light weight and plenty strong.

 

[CUZICAN]

Nice work !!! Can I make a suggestion for easy access, you may want to put a piano hinge on the rear part so that you can lift it up like a lid for more access, and if you have a taller item that you are transporting.

I actually had that thought, but unfortunately the little side wing for the bolts on the rear section hit the roll bar stopping it from folding.

 

[Bad_Bronco]

I actually had that thought, but unfortunately the little side wing for the bolts on the rear section hit the roll bar stopping it from folding.

If you cut a new front piece, and include the two bolts on the rear piece, then you can put a hinge where you have the cut now, and be able to lift and secure from underneath. When I made mine, I used the side as a template and ran it all along the side to the tailgate. Then I made a flat top with hinges, secured under so no one can open it unless truck is unlocked. Hard to see in my pics, but it is strong, and secure when the top is on or off. Also made a top so when I have my fridge in, it is also secure when top off......

 

[broadicustomworks]

Looks great! I love it when these DIY projects people do turn out nice and finished.
Vinyl is good and taut, curved edges look great. excellent work!

 

[Br0nc0babe2021]

do any of you DIY'rs whom have designed and made your own hard tonneau covers for the 4 door broncos have measurement/specs? My brother is a fabricator. We are trying to fabricate similiar using fiberglass- so secure/weatherproof. My only problem is I'm not amazing at measuring and he lives 5 hours away. hoping to mock up a template for him. I will post photos and if all turns out, maybe be able to fabricate for others
Thank you, in advance. I really appreciate it. I absolutely HATE my vinyl tonneau and with one seat down and the top off, it flaps all over the place.

 

[Brad Fx]

@CUZICAN what pet barrier / metal window grid is this? Can you still recline the rear seats? I looked at a couple like this, but you could not recline.

 

[CUZICAN]

@CUZICAN what pet barrier / metal window grid is this? Can you still recline the rear seats? I looked at a couple like this, but you could not recline.

I'm pretty sure it is the Broaddict one, I can verify when I get home. My seats are reclined all the way, but I did have to make a small mod to make that happen. I just picked up a couple spacers and a couple longer bolts and installed them in the lower hole, causing the panel to sit at an angle. It's still really close and the panel would rattle against the seat on bumps, so I wedge some padding between the seat recline lever and the panel and all is quiet now.

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