Pictures of $90 Plywood Tonneau Cover

bluesun · 05-21-2004, 10:16 PM

Ok, since no one was really making one yet, I had to go with plywood to get some security. Works with utilitrac with no drilling. Of course, if you actually want to use the track, you'll have to pull it out. Odd thing was, I actually had to use the built in bed hooks to keep the plywood from sliding out. Ironic, huh?

Home Depot: 2x35 for two sheets of plywood, 3/4 inch. Finished both sides as unfinished was only 2 bucks cheaper. They will do two cuts for free, but I hadn't measured so cut at home. 1 gallon flat black latex paint, 20 bucks. Guess you could have used spray paint. Don't intend to have it last forever, but looks ok now. Hasn't flapped in the wind at 80 yet, but then I had the stereo on.

Grand Total: 90 + tax.

fish_head · 05-21-2004, 10:19 PM

Doesn't look bad! Very crafty. Thanks for the pics!

bestatchess · 05-21-2004, 10:38 PM

Not bad at all. I remember when you could fill the bed of a truck with plywood for $90.

Orlando Titan · 05-22-2004, 04:57 AM

You think you can get us a group discount

Looks good.

casique · 05-22-2004, 05:30 AM

Give Retrax Bed cover a call, they have a roll-up cover that fits the track system.

VShortt · 05-22-2004, 05:43 AM

Your modification looks quite nice. I am impressed. I do have 1 suggestion though. Since the front sheet of plywood sits in a channel on its long side and the rear sheet does not, inevitably the rear sheet is going to begin bowing much quicker than the front sheet and the seam is not going to be level. I am gonna go out on a limb here and see if i can produce a little drawing for you that illustrates a fix for this. See attachment

FRD ETR · 05-22-2004, 08:43 AM

Nice job I had wondered how something like this would look. Just curious besides the added security will this improve mileage any?

FLfinfan · 05-22-2004, 12:42 PM

Nice idea.

1BadTitan · 05-22-2004, 07:50 PM

That is great!!! I'm doin' it. I'll post pics ASAP. One thing I'm gonna add is I'm gonna support the center to prevent sag.

rrumaner · 05-22-2004, 08:05 PM

Only problem I see with this setup is that you cannot use any of the utilitrak accessories. I have the divider and was hoping that it would be ok to keep that in place, but the size of the clamps that hold it would keep me from using it.

**goathead** · 05-23-2004, 07:08 PM

i actually have been thinking of doing this. i have other posts on this subject.

i do have a ? for you. with that 3/4" plywood, does that fill the utili-track up pretty tight? i looks like it does. the reason im asking is i want to cover the plywood w/ a felt-backed vinyl and use spray adhesive and staples on the underside for added tightness. also i think the vinyl when pushed against itself in the middle, will create a small seal.

it looks great. now i gotta get off my a$$ and do mine.

steve

bluesun · 05-23-2004, 10:24 PM

Thanks for the positive response, I'll try to answer all below:

Retrax was like 800 and looks sort of weird. Would have to see it in person, and plus I don't want to drill.

VShortt: Thanks for the drawing. One problem that you could not have forseen is that the sag makes it a little tough to actually line up the front, so your bracket would need a little lip to make it slide up easier.

FRD ETR: I would check the mileage if it were easier to remove and all. Was planning to do that with the instant mileage on the NAV and cruise control. But the plywood isn't so easy to open...

1BadTitan: Yeah, a support would work nice, could in theory even use the extra plywood leftover and slide a nice 3 foot piece in there. If I had more time I might have looked into it.

rrumaner: You are correct, it fills the utiltrack. But the other covers required that you remove it. At least now I can pull it out and use the tracks if needed.

GoatHead: Yup, 3/4 fills it pretty tight. I think plywood is 1/8 less then stated, and I think the track is right at 3/4. But vinyl would fit, but however, would it survive being slid along the track? As for a seal in the middle, I trimmed the boards so I wouldn't slam it against the gate (still does a wee bit). But you could shim it at the tail gate to get a strong seal in the middle. I expect wetness, and worse, dust to get in everything. If not, keep it in the truck.

pagerdaddy · 05-23-2004, 10:52 PM

Bluesun, I think it looks damn good to have been made from plywood.

Have any of you guys considered any other materials besides wood?

I remember pricing some aluminum plate one time, and it was quite
expensive when you got into the thicker pieces, but still not as much as
some of these covers that are out there.

I would think that with all the plastics that are available these days you
could find something like that in big sheets which could be cut to fit in
your tracks. Just an idea.

Steve

Titan69 · 05-26-2004, 10:33 AM

you could also datto the ends of the plywood with a router and then they would lock together in the middle.

titanmike · 05-26-2004, 03:54 PM

You could use a couple clips that roofers use to put two pieces of plywood together. It would keep the two joints even. Its hard to explain what they are, but if you haven't seen them before just ask the guy at the home depot or where ever you shop. You could also screw a piece of 2 x 4 to the plywood the width of the plywood making it sort of look like a "T" (not the flat way) They would help reduce sagging considerably.