How To: Modify Stock Tonneau to Fit Toolbox - Chevrolet Colorado & GMC Canyon Forum
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Old 01-22-2010, 04:57 PM   #1
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How To: Modify Stock Tonneau to Fit Toolbox

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The community here at 355nation.net urges you to please use caution and seek professional assistance when performing modifications to your vehicle. Before attempting any modification it is advised that you refer to your Colorado or Canyon service manual or contact a certified mechanic as not all GMT355 trucks are the same. The staff and the associated members are in no way responsible for any damages, injuries or other harm inflicted to your vehicle or yourself which may result in attempting these modifications. The posts and content presented on this site reflect in no way the views of 355nation.net or it’s ownership.




A 355nation How To presented by
radojim

Project Name
How To: Modify your stock tonneau cover to fit an in-bed toolbox

Skill Level
Easy - Moderate

Project Vehicle
Make: Chevrolet
Model: Colorado
Year: 2005
Engine: 3.5L
Power windows: Yes
Sun Roof: No

Tools Needed
Tape Measure
Hacksaw
Sharpie
Drill & Bits (size will vary - i used 11/64)
Razor Blade
Sewing Machine (or local upholstery shop!!)
2 Bungie Cords (will vary - i used 32''ers)

Project Time
2-3 hours

Project Cost
2 bungies @ $2.99 each
1/2 hour shop rate @ upholstery shop ($30+/-)

1. Measure for new tonneau size

2. Mark about 1/2'' in front of 2nd bar (middle bar measuring towards cab) with tonneau rolled up, cut with hack saw


3. Overlap the 2 halfs to new desired length. This will vary depending on brand/size of your toolbox. Mine overlaps about 1/2'' behind 1st bar.


4. Cut out overlaping section. This will be the new size of your tonneau


5. Test fit




6. Remove tonneau, unroll upside down and mark the material atleast 1'' from cut edge on both driver and passenger side (from front or back, no order, they both need marked)





7. With a straight edge connect your markings across the cover and cut out section. the extra inch is just room for error while sewing. you will have slack.

8. I dont have a sewing machine - nor would i know how to use one so the local upholstery shop did the sewing for me.

-lay the 2 halfs (top of cover touching top of cover) with the cut ends lined up so after sewing it can be opened like a book.

Back from the shop



So how do you get to the toolbox handles?

9. carefully drill out tonneau frame to hook bungie through - making sure not to drill through cover itself. hook other end through frame bracket. this should hold the flap at highway speed




Before


After

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Last edited by radojim; 02-26-2010 at 08:15 AM.
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Old 01-22-2010, 05:49 PM   #2
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Re: How To: Modify Stock Tonneau to Fit Toolbox

Very cool man and that looks really useful for the guys with tool boxes.
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Old 01-22-2010, 06:11 PM   #3
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Re: How To: Modify Stock Tonneau to Fit Toolbox

i had this in the back of my head, just couldnt find a toolbox i liked so didnt go ahead w/ it
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Old 02-25-2010, 06:09 PM   #4
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Re: How To: Modify Stock Tonneau to Fit Toolbox

damn wish these pics worked
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Old 02-25-2010, 09:44 PM   #5
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Re: How To: Modify Stock Tonneau to Fit Toolbox

What the hell happened to the pics???
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Old 02-26-2010, 08:15 AM   #6
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Re: How To: Modify Stock Tonneau to Fit Toolbox

pics back up fellas, my bad
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Old 02-26-2010, 08:32 AM   #7
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Re: How To: Modify Stock Tonneau to Fit Toolbox

Badass job Jim!
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Old 10-25-2011, 06:06 PM   #8
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Re: How To: Modify Stock Tonneau to Fit Toolbox

Would anyone want to do this for me and ill give you the dimensions of the toolbox and bed. I just don't have enough time to do between work and school. I have no free time and winter is coming up and I don't want all the snow laying in the bed.
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Old 10-25-2011, 10:20 PM   #9
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Re: How To: Modify Stock Tonneau to Fit Toolbox

Nice, very well thought out!
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Old 11-12-2011, 06:44 PM   #10
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Re: How To: Modify Stock Tonneau to Fit Toolbox

looks good!
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Old 10-16-2013, 03:24 PM   #11
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Re: How To: Modify Stock Tonneau to Fit Toolbox

I'm going to be doing this Friday. I just got a tool box at tractor supply for $149. It's not a low profile one, but I wanted to have it be up higher so the handles would be above the cover. My cover is one of the shitty button on ones so that complicates things a bit. I figure measure twice cut once, see it back up and it'll be good. Now I'll have a locked up waterproof box to put stuff in and less crap in my back seat.

I'll throw up some pics of the process as I finish.
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Old 10-20-2013, 08:00 PM   #12
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Re: How To: Modify Stock Tonneau to Fit Toolbox

So I bought this the other day at tractor supply:

Started the install Friday afternoon and finished Friday around midnight. Instal of the tool box was easy, drill two holes, insert J hooks, good to go:


Filled it up with all this crap that was either in the cab or rolling around in the bed:


Old busted ass hinges:


Cut frame to fit:



New hinge setup (bought 10 screws and needed 12...)


Completed frame:


Even with such a simple project something dumb has to happen... Peice of shit aluminum c-clamp broke right in half:


Tarp on presewing:



Complete! Decent job for a redneck who doesn't really know how to sew:
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Old 04-14-2015, 10:37 AM   #13
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Re: How To: Modify Stock Tonneau to Fit Toolbox

I can't believe no one has commented on this. I love it! I'm thinking about doing it


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