How to Make a Tonneau Cover for a Truck
Tonneau covers are a type of hard cover for trucks that covers the rear bed. You can buy a tonneau cover for your truck, or you can make one by constructing a wood frame and attaching it to the side rails of your truck. Making a tonneau cover to fit your truck requires the proper measurements, plus wood and hardware for the frame.
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Things You'll Need
- Tape measure
- Three 8-foot long 2-by-4 boards
- 4-foot-by-8-foot ¾-inch plywood sheet
- Circular saw
- Power drill
- Screws
- Hex bolts
- Fender washers
- Locking washers
- Socket wrench
- 2 "T" hinges
Instructions
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1
Measure the width and length of your truck bed with the tape measure. Measure one of the 2-by-4 boards to the width and measure two to the length. Make a mark with the pencil and cut to the required length with the circular saw.
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2
Remove a 3 ½-inch long by ¾-inch deep section from each end of the 2-by-4 that is cut to the width. This board will sit on top of the two side boards.
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3
Set the side pieces along the side rails and mark the location of the factory holes. Drill a hole through each 2-by-4 on the marks with the power drill.
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4
Insert a fender washer and locking washer over the hex bolts. Insert the hex bolts into the bolt holes in the 2-by-4 boards. Secure the boards to the side rails by tightening the bolts with the socket wrench.
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5
Place the 2-by-4 with the notched ends on the two side boards at the front of the bed. The board should be placed directly behind the cab. Secure the board to the side boards with screws.
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6
Measure and cut a piece of ¾-inch plywood that matches the width and length of the truck bed. Subtract 3 ½ inches from the length and cut the plywood with the circular saw. You may need a second piece of plywood to cover the bed.
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7
Set the plywood on top of the side boards. Place the "T" hinges on the 2-by-4 and plywood. Secure the hinges to the wood with screws.
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Tips & Warnings
Attach latches to the end of the side boards to keep the cover locked down when traveling.
Paint the tonneau cover to match the color of your truck.
