Hey guys. Thought I'd do a little writeup on my latest project. Wanted a hard lockable tonneau since I have a soft top and want to run windowless in the summer. Couldn't find anyone who makes them so I decided to build my own with some inspiration from others on here that made theirs. Also wanted to ditch the spare on the gate, so this worked out.
Sheet metal is 14g steel. Framing/supports are 3/4" 12g square stock from Menards/Lowes. Had a local sheet metal shop get me the steel and put the bend in the front panel:
From there, I cut/shaped/framed my first version:
Worked fine, but unfortunately, the outside corners came into contact with the windows before the lid was fully opened. Had to redesign and came up with V.2:
As you can see, I decided to mount the stock tire carrier to the lid. Had to add a couple braces to the hatch:
From there I just had to clean it up a bit and paint it. Used a Rust Encapsulator and Chassis Black from Eastwood. Not super happy with the coatings, but they'll do for now:
Added some carpet runner, that I also made floor mats with, from Menards for protection and sound. Also relocated the rear top support bar to the cover. Still can't lower the top all the way without detaching the front support bar. I don't like how the stocker folds up anyways, so I'll just remove it or get a frameless if I want to go topless. Just have to add a couple drawer style locks and finish the corner pieces before it's top down season. Inside dimensions are 3'x3'x15.5".
Turned out pretty sturdy. I'm 150# and I stood on top of it and jumped up and down without moving it much. I might make a different one this summer with a couple small changes. Also have a version in mind that allows the entire center section to be removed to use the back seat.
Here's a few shots of it finished... for now: