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vortmax

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Discussion starter · #1 ·
I want to build a flush cover and I'm trying to brainstorm some ideas. I want to float this out there for anyone (especially those that have made one) to comment on.

Design wise I want the cover to:

1. Sit flush
2. Be mostly weather tight
3. Be constructed of panels, allowing me to expose part of the bed while keeping the rest covered.
4. Not have any type of bracket that stays mounted to the bed when the cover is off (I have bike racks that clamp to the rail.

My idea is to make the cover out of hinged panels. If I go with 4 panels, I would hinge them in groups of 2. If I did 3, I would hinge one set and leave the 3rd by itself (does that make sense?).

To hold them in place, I would put angle iron on the edges of the cover that would rest on top of the bed rail to support the cover. I could use some sort of thin weather striping under it to seal the cover and protect the paint. To lock the cover down, I could have some sort of clamp mounted to the bottom of the cover that would clamp under the rail. I've been trying to thin about how to clamp/unclamp from the top, but may just have to only clamp one side of each set so that I can just flip open one side to reach the clamps.

For materials, I was thinking about 3/4 MDF covered in something....but I'm not sure what. I thought about glassing it, but something soft like vinyl would make weather proofing the hinge area easier.

Anyway, what do you think? Any obvious problems you can see? Any ideas on how to improve the design?
 
Discussion starter · #3 ·
That looks to be about what I want... Except making the cover support itself instead of using l-brackets.

I think I figured out how to secure it (and lock it) but the flush, sealed hinge is still giving me problems. I'm interested to see how you go about it.
 
Discussion starter · #4 ·
So last night I had a great idea. I can just make panels in whatever size I want, cover them to waterproof, then run a strip of 2" marine velcro along the top (width wise) edges.. Then I'll just make a few strips of velcro backed marine vinyl to match. So each panel will be sealed to the next by this velcro strip, which will also act like a hinge. So I can "break" the cover at any seam to get into the bed, AND I can make up panels of different sizes and change configurations really easily.

I still haven't worked out how I'm going to fabricate the panels. I'm thinking 3/4 mdf or hardwood ply (for strength), edged with aluminum U channel (h- channel on the short edges to rest on the bed rail). To wrap it, I'm thinking a single layer of fiberglass to seal, then vinyl on the top panel, although I have considered glass only. My other thought is that if I glass it, I could use 3/4" foam instead and keep the weight down.
 
#5 ·
sounds like you have a good game plan going!

I would avoid using fiberglass--it'll be heavy, and difficult to get it flat without a lot of block sanding. I would use 1/2" plywood in 3 panels, wrap them with an all weather vinyl, use aluminum L-channel screwed to the ends to let it sit flush, with a thick "foam" weather seal to keep it from scratching the paint.

try to get L-channel that's an inch or so wider than the wood, so that there's a "lip" that also sticks down. then you can get some small cheap C-clamps to hold the panels in place, fast and easy to install and remove. the velcro overlap on the panels is a good idea too for the hinges.

cool thing with vinyl, is you can pick out any color/design that you want. I'd get something like this myself...

Image
 
Discussion starter · #6 ·
That is a good idea using oversized L-channel and clamping it. My other thought was using a padded strip magnet for a weather seal, sticking the cover to the rails.

I'm also trying to figure out how to get the top vinyl to go over the L-channel, hiding the seam between the plywood and the metal.
 
#7 ·
vortmax said:
That is a good idea using oversized L-channel and clamping it. My other thought was using a padded strip magnet for a weather seal, sticking the cover to the rails.

I'm also trying to figure out how to get the top vinyl to go over the L-channel, hiding the seam between the plywood and the metal.
Click to expand...
well, you could cut the fabric several inches longer than needed and wrap it around the L-channel, then staple it to the wood on the underside. use double sided foam tape on the L-channel to hold the fabric tight to the channel so it'll still allow the L-channel to sit flush with the bed rails.
 
#8 ·
I to have been thinking about making my own. Mind is street/strip affair and weekend warrior only. Weight and aero is a priority to me. I'm thinking of doing a aluminum alloy setup that is one piece. It will be permanently clamped to the box in a flush mount fashion.
A local metal shop has sheets that will fit my box. They will cut it and do a 90 degree 2 " bend around the edges. I can get various thicknesses. I may go fairly thin and use some aluminum brackets underneath for braces to prevent sagging. They will cut and bend this for $180. I'll paint it myself. What do you guys think?
Tom
 
Discussion starter · #9 ·
For a single sheet of steel, I would put in a few cross members. Either tack weld them in place or flush rivet. I would think 2 or 3 cross members plus the bent edges would do it.

How do you plan on supporting the cover in the bed? I have some interesting ideas using hood pins that might work well for a single sheet cover like yours.
 
#11 · (Edited)
Check out my cover. It's pretty simple. Two 1/2" sheets of plywood, shaved 2x4s for bracing, upholstery, a piano hinge, aluminum channel brackets to sit it flush to the bed rails, two bungie cords to hold it to the front bed tie downs. Folds in half, easy to remove/install all by myself. Looks way cool! If you're interested in making one yourself I can get you the recipe and more pics.

Image


Image
 
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Discussion starter · #12 ·
That looks great! I'd love to hear more about the material you used to cover it and how you secured it to the plywood. Also, it looks like you attached aluminum channel to the bedrail to support the cover. How did you attach it to the bed?
 
#13 · (Edited)
Well, a friend of mine upholstered it. He used tonneau cover material. It's a little thicker than the vinyl used for roof top covering. It's just wrapped around the edges and stapled on. There is some fuzzy material in the center sections (underside) to make it look nice. It's been on my truck over 7 years and still looks great.

I applied wood sealer to the plywood before covering it. The aluminum channel is riveted to the bed rails (drilled holes first).

I like it folding in half. I can move it on and off myself easily. I can leave it on, flip it up (weighted down with a sandbag) to put something in the bed to carry it. Or I can remove it all together and put it in the bed with whatever else I need to carry if it's larger than the open half. Can't do that with a fiberglass one-piece cover...
 
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#14 ·
vortmax said:
For a single sheet of steel, I would put in a few cross members. Either tack weld them in place or flush rivet. I would think 2 or 3 cross members plus the bent edges would do it.

How do you plan on supporting the cover in the bed? I have some interesting ideas using hood pins that might work well for a single sheet cover like yours.
Click to expand...
Hood pins are a great idea! That would make it easy to remove/install. I was going to use some old C-clamps from a previous cover. What are you guys using for clearance around the edges of the box? I was thinking 1/8" around with a gasket.
 
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vortmax
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