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Old 05-12-2009, 10:34 AM   #1
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How To: Build your own folding Tonneau.

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A 355nation How To presented by
burn

Project Description
Building your own folding tonneau cover

Skill Level
easy

Project Vehicle
Make: Chevrolet
Model: Colorado
Year: 2006
Engine: 3.5L
Transmission: Auto
Power windows: No
Sun Roof: No




So as some may recall - back when I first got my truck I built my own tonneau. Heres a pic of it:




Well it started to pull apart because I just stapled it on and didnt have it stitched down the middle. Also it was a PITA to remove because it was so big. Also if I went somewhere I couldnt put big stuff in - Id have to take it off / leave it at home. Because of this, I have decided to make it a folding tonneau. I ripped off the vinyl and cut it in half, and added some hinges. Here are some pics:











As you can see, its clamped at the front of the box to hold it in place. The rear just sits on the horns for where the tail lights are. I added cross-braces at the rear corners because I am going to add straps to clip onto the loops to hold it down. Then, when I need access I can just flip it forward.


I picked up a bungee strap to use as a tie-down. I cut it in half, and measure the extended length to determine the length. Its 13" from the top of the box rail to the bottom hook.... so I made the straps 10" at their relaxed state. Heres some pics:





took a few quick pics... must have started snowing since I put it on a few hours ago... the fabric is actually the same fabric as in the pic of my original tonneau. anyways, heres some pics:




for anyone curious about why im not happy about the results; its because the frame does not meet up snug to the tailgate (when I split it, I had to sand it a bit to get it to sit square) and the fabric seam in the middle isnt perfect (my sewing skills are apparently typical of a 27yr old male - LOL)


Took a few pics this morning of how the strap works, and of it folded. Sorry the pics suck, I took them with my BlackBerry:

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Last edited by rshadd; 08-02-2012 at 09:01 PM.
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Old 05-12-2009, 10:47 AM   #2
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Re: How To: Build your own folding Tonneau.

it's still snowing up there? damn.

That's a pretty good build, looks good man. just courious how much did it all cost you in the end?
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Old 05-12-2009, 10:56 AM   #3
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Re: How To: Build your own folding Tonneau.

The wood was like $20, the clamps were about $20, and the material was about $40.
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Old 05-12-2009, 11:38 AM   #4
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Re: How To: Build your own folding Tonneau.

good idea! u saved a whole bunch of money with that!
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Old 05-12-2009, 02:40 PM   #5
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Re: How To: Build your own folding Tonneau.

Nice going
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Old 05-13-2009, 09:10 AM   #6
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Re: How To: Build your own folding Tonneau.

under $100...not bad sir
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Old 05-13-2009, 05:49 PM   #7
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Re: How To: Build your own folding Tonneau.

if u no how to use fiberglass resin u could have that thing looking amazeing
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Old 05-13-2009, 09:13 PM   #8
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Re: How To: Build your own folding Tonneau.

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if u no how to use fiberglass resin u could have that thing looking amazeing
I built the body kit on my car from cardboard & fiberglass from scratch:









Ask CodeRed - he can vouch for me
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Old 05-13-2009, 09:49 PM   #9
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Re: How To: Build your own folding Tonneau.

not bad from scratch burn
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Old 05-13-2009, 10:08 PM   #10
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Re: How To: Build your own folding Tonneau.

how does it hold up to weather, specifically the wood? Would this be easy/recommended with aluminum maybe?
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Old 05-13-2009, 10:21 PM   #11
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Re: How To: Build your own folding Tonneau.

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how does it hold up to weather, specifically the wood? Would this be easy/recommended with aluminum maybe?
its actually been on for 2 years - and only the corners show any wear from weathering... but would easily last another 2 years.
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Old 05-13-2009, 11:36 PM   #12
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Re: How To: Build your own folding Tonneau.

your good burn. im gonna have to steal this idea
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Old 05-14-2009, 02:19 AM   #13
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Re: How To: Build your own folding Tonneau.

great work man. cant believe its still snowing up there! hows it do in rain? alot of leaking on the sides or did you do some sort of weatherstripping?
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Old 05-14-2009, 08:29 AM   #14
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Re: How To: Build your own folding Tonneau.

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great work man. cant believe its still snowing up there! hows it do in rain? alot of leaking on the sides or did you do some sort of weatherstripping?
It hasn't snowed in over a month.... those pics are just old. Holds up great in the rain. Its not waterproof though - was never intended to be. I just wanted it to keep 600lbs of snow out during the winter.
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Old 05-14-2009, 10:37 AM   #15
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Re: How To: Build your own folding Tonneau.

looks good man
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Old 05-14-2009, 10:48 AM   #16
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Re: How To: Build your own folding Tonneau.

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It hasn't snowed in over a month.... those pics are just old. Holds up great in the rain. Its not waterproof though - was never intended to be. I just wanted it to keep 600lbs of snow out during the winter.
ahh. well if you do want more weather protection it could easily be done! the universal weatherstripping they sell is just a 3m stick on and works really well. you prob dont want to bother but just incase someone else makes one and does just wanted to throw that out there.
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Old 05-14-2009, 03:00 PM   #17
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Re: How To: Build your own folding Tonneau.

What if you built the brace like the one burn did. only put ply wood on it in sections bc one wouldnt do it then fiberglass over it. Clamp it down as you would a regular tonneau cover. then go get shocks from autozone or a junk yard and do it that. Think it could work?
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Old 05-19-2009, 08:27 PM   #18
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Re: How To: Build your own folding Tonneau.

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What if you built the brace like the one burn did. only put ply wood on it in sections bc one wouldnt do it then fiberglass over it. Clamp it down as you would a regular tonneau cover. then go get shocks from autozone or a junk yard and do it that. Think it could work?
could def work. if your good with fiberglass i dont see why not. just have to mount some swiveling brackets for the rear, actuator mounts, and some form of locking mechanism. hahaha just realized how much easier it was to buy mine.... come to think of it there are some tonneaus out there that wouldnt cost all that much more.
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Old 05-21-2009, 01:33 AM   #19
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Re: How To: Build your own folding Tonneau.

lol true!
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Old 05-24-2009, 09:03 PM   #20
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Re: How To: Build your own folding Tonneau.

good info, never would of thought that.
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