Posted: Oct 12 2004 at 11:25pm | IP Logged
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I built it in 2 pieces so it would be easier to take on and off by myself. It was pretty simple to build, although I admit I took a lot of time being very precise with my measurements because I wanted it to fit really tight. I was initially worried about the possibility of it flying off while traveling at Hwy speeds, so I decided to screw eyebolts into the wooden frame and secured those to the truck bed tiedowns with bungee cords.
It required 2, 4x8 sheets of 1/2" plywood. I also used 4, 2x4s for the frames and 4 galvanized corner brackets to keep everything nice and square. The frames are basically 2 rectangles, ...2x4s screwed together with deck screws and corner brackets (the 2x4s on their sides, not laying flat.)
I cut the plywood so that it would overlap the bedrails apprx 1 1/2" - 2". (the cover is resting on the bedrails, the 2x4 frame fits down in the bed to keep it centered and fitting snug.) I also added a strip the plywood apprx 5-6" wide to the underside of the back cover (in the middle) to act as a "lip" for the back of the front cover to rest on. This was another attempt to prevent the back cover from lifting off at high speeds and had the added benefit of making it even more watertight. (I added a piece of rubber weatherstripping between the 2 halves.
I attached the plywood to the frames with more deck screws. Countersunk them just a hair, and is even a good idea to cover them with a little wood putty and sand smooth. I learned the hard way, every imperfection will show thru the vinyl once it is glued on. I used marine grade vinyl from Hancocks fabric, and 3M contact cement from Lowes. CAUTION: the vinyl is very easily scuffed/torn. I scraped mine in 3 places just while I was building it. After glueing the vinyl, I folded it under and stapled it......I think I spent about $100 on all the materials. PM me if you have any more questions...G L
__________________ SE Kingcab Smoke Gray, Big Tow, K&N filter, Silverstar lamps, Peragon hard tonneau, (Sirius SR, 350W Alpine amp, Polk spkrs, 2 RF 8" subs, custom box)
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