Hard tonneau build - Jeep Wrangler Forum

Go Back   Jeep Wrangler Forum > TJ Jeep Wrangler Forum > TJ Build Forum

Join Wrangler Forum Today



Reply
 
Thread Tools

Please support our sponsors and let them know you heard about them on WranglerForum.com
Old 03-02-2014, 06:56 PM   #1
Jeeper
 
Atumant's Avatar
 
Join Date: Jan 2014
Location: New Lenox, IL
Posts: 142
Atumant is on a distinguished road
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
Atumant is offline   Quote
Old 03-02-2014, 07:14 PM   #2
Jeeper
 
brandon-99tj's Avatar
 
Join Date: Sep 2012
Posts: 755
brandon-99tj is on a distinguished road
It looks really good. Any ideas on how you are going to finish the corners?

brandon-99tj is offline   Quote
Old 03-02-2014, 07:20 PM   #3
Jeeper
 
Tim Stines's Avatar
 
Join Date: May 2012
Location: Harrodsburg Indiana
Posts: 587
Tim Stines is on a distinguished road
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.

http://www.wranglerforum.com/f330/my...ml#post9534378
Tim Stines is offline   Quote
Old 03-02-2014, 07:42 PM   #4
Jeeper
 
Atumant's Avatar
 
Join Date: Jan 2014
Location: New Lenox, IL
Posts: 142
Atumant is on a distinguished road
Quote:
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
Atumant is offline   Quote
Old 03-02-2014, 08:01 PM   #5
Jeeper
 
Medixtj01's Avatar
 
Join Date: Jul 2013
Location: Pennsylvania
Posts: 1,226
Medixtj01 is on a distinguished road
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, 4.0 with 32rh, Zone 4.25" lift, 33x10.5 BFG AT KO

My Build thread
http://www.wranglerforum.com/f322/me...l#post19318217
Medixtj01 is offline   Quote
Old 03-03-2014, 08:06 AM   #6
Jeeper
 
tulman22's Avatar
 
Join Date: May 2011
Location: SE Atl
Posts: 42
tulman22 is on a distinguished road
Subscribed. Looking to do something like this also.
__________________
US NAVY (SPOOK) - RETIRED
tulman22 is offline   Quote
Old 02-23-2015, 07:14 PM   #7
Newb
 
Join Date: Jan 2014
Posts: 6
Oppugnall is on a distinguished road
Awesome design! I've been looking into something like this. My plan is to redo cage deleting rear rollbar, down the road putting a fuel cell in trunk.

Oppugnall is offline   Quote
Reply

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off




Download our Mobile App

» Featured Product

All times are GMT -5. The time now is 02:16 PM.


User Alert System provided by Advanced User Tagging v3.1.0 (Pro) - vBulletin Mods & Addons Copyright © 2016 DragonByte Technologies Ltd.
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2016 DragonByte Technologies Ltd.

Jeep®, Wrangler, Liberty, Wagoneer, Cherokee, and Grand Cherokee are copyrighted and trademarked to Chrysler Motors LLC.
Wranglerforum.com is not in any way associated with the Chrysler Motors LLC
« Back

Enter your email address:

Delivered by FeedBurner