Truck Aero, Bed cover DIY tonneau?

[Bajascoob]

Used EMT conduit, 4mil plastic sheeting.

[Daniel]

I didn't do anything fancy. About $125 in lumber, hardware, & paint. Still a work in progress. More of a hillbilly tannau than anything. I am hoping for a 10% increase in HWY mpg (I currently get about 12, so every little bit will help)

[Daniel]

I have a late 1988 Chevy pick-up I rarely use. Most of the mileage is going to my son's soapbox derby races. I do also use it for basic home maintenance projects.. the V8 is a bit overkill for my needs but is what I could afford at the time.

[Daniel]

I started my tonneau project by looking on the web for ideas, then one day started designing it in my mind as I walked around home depot grabbing lumber and parts.

[Daniel]

I learned a few things along the way.. I live in a wet climate, but felt primer & paint would be enough.. I should have went with a sealer. I now need to add some braces to correct some warping.

[Daniel]

I am also posting these messages because it said I needed 5 posts in order to link to my images.

[Daniel]

So here is my project so far.

[Chris D.]

How are you securing it to the bed?

[Daniel]

I bolted aluminum "L" brackets on each side and ran a 2 x 6 across so I would have good support for the front hinges. I just used furring strips down each side to support the cover when it's closed.

I have experienced a little bowing toward the tailgate & screwed on a few furring strips as support ribs. I think the bowing has to do with the moist climate I live in and I did not seal the interior. That is this week-ends project.

[joemann]

Daniel, That's kinda what I had in mind. All the words about bondo and poly, etc., are great for the super slick pro look, but just need something functional to keep the weather off cargo. I was thinking just one hard tonneau top, light enough to hinge up against the cab when open. I was thinking of getting some 1x4 pine and cutting a slight curve in it to promote rain water drainage, then potting it 16" on center and covering it with the lightest weight ply, topping that with glue down plastic available from Home Depot or Lowe's for about $30 per sheet in the panelling section of the store(s). I have an 8' long bed (new Chevy Silverado work truck), so i would need two sheets, place one full sheet in the center and cut two side sheets for the 4' wide one to overlap down each side to make up the difference the 4-footer doesn't cover. Then prime and high gloss enamel spray it to match the truck. I'd like to be strong enough to support walking on it but that may make it too heavy a plywood issue and i don't foresee needing to walk on it except to parades during new orleans mardi gras season when you want a high perch behind the roadside crowds. anyone have any thoughts on this construction? i'd like to lock the booger at the tailgate but tailgate has no lock, so go figure. it won't be as pretty as bondo/fiberglass job, but i'd prefer to avoid that stuff. looks aren't THAT important to us older dudes (especially if u got a sportscar u drive for all other occasions when only cargo is -- hopefully -- a woman).