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Old 03-02-2014, 07:56 PM   #1
Atumant's Avatar
Join Date: Jan 2014
Location: New Lenox, IL
Posts: 60
Images: 28
Hard tonneau build

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:

'06 Wrangler Sport
'04 Nissan 350Z
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Old 03-02-2014, 08:14 PM   #2
brandon-99tj's Avatar
Join Date: Sep 2012
Posts: 735
It looks really good. Any ideas on how you are going to finish the corners?

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Old 03-02-2014, 08:20 PM   #3
Tim Stines's Avatar
Join Date: May 2012
Location: Harrodsburg Indiana
Posts: 587
looks great and is certainly unique I like the spare tire being on it too
There are many obstacles that life throws at you, but you gotta make like a jeep and crawl over them and continue on.

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Old 03-02-2014, 08:42 PM   #4
Atumant's Avatar
Join Date: Jan 2014
Location: New Lenox, IL
Posts: 60
Images: 28
Originally Posted by brandon-99tj View Post
It looks really good. Any ideas on how you are going to finish the corners?
Going to reuse the pieces I cut off the large sheet for those corners. I have one mostly made already. 2.75" hole in the corner to go around the roll bar and bolt it to the tub like the rest of the cover.

Thanks, Tim.
'06 Wrangler Sport
'04 Nissan 350Z
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Old 03-02-2014, 09:01 PM   #5
Medixtj01's Avatar
Join Date: Jul 2013
Location: Pennsylvania
Posts: 861
Subscribed. Definitely looking forward to seeing how you do the removable section for the seat. I'm going to make an instatrunk but not sure if I want to make it so I can add a section and make it cover the entire bed
2001 Sahara 3 speed auto
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Old 03-03-2014, 09:06 AM   #6
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Join Date: May 2011
Location: SE Atl
Posts: 42
Subscribed. Looking to do something like this also.

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