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Old 05-01-2010, 09:53 PM   #5 (permalink)
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Join Date: Aug 2009
Location: Winnipeg, Canada
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Sourced some black coroplast for 30 dollars for 2 4x8 sheets. Covered the frame with it and riveted it on. The rivets tended to pull out of the plastic a little too easy so I made washers out perforated strapping and uses the strapping to edge the major stress areas around the corner bends. 1/8" pop rivets are used to fasten the entire perimeter of the covering.

More pics.....

Interior view showing framework. Pipe insulation keeps the box rails from getting beat up.

Exterior showing coroplast. My first time working with it. I found that a heat gun and carefully bending the radius of the corners prevented major kinks.

A few pics of the back showing the fastback style raised edge. This was done in an attemt to "boat tail" air flow. Some bubbling issues with the plastic on the sides. I may add additional braces and fasten it on the sides.

Here it is on the truck. There are four stakes that drop into the trucks stake pockets. Ratchet straps fasten it down into the the bed from the cargo tiedowns in the box.

If it works well I will design a hinge from the front to allow it to raise up like a solid tonneau cover.
I will be very closely monitoring fuel consumption for the next while and will post results here as I get them. Barring no major headwinds, typical fuel consumption ranges from 19-21mpg hwy most times.

Total cost to date for supplies (not including tools) $70.00 tax included.
Comments and suggestions welcome!!


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1994 electricfly EV conversion 36V/450A/60km/h
1997 Suzuki Sprint hatch (parts car?)
1998 Geo Metro sedan 1.3L auto (the wifes)
2009 GMC Sierra 27us/mpg best yet (still workin on it)

Last edited by swede; 05-01-2010 at 10:00 PM..
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