Has anyone ever tried to make their own tonneau cover? I'd like to make a metal one just like the Diamondback Covers. Anyone have any sort of plans or pictures with steps and stuff showing ways to mount and lock it on the bed?

 

Back in the early '70s, I helped make a couple using 3/4 plywood and some 2x2s (marine grade or you could treat the wood after glue up) and we made them in two pieces, a joint about 1/2 way back .... but you could make it one long piece. Mounted a piece of angle lengthwise in bed below side rail to support underneath the 2x2s and put spring loaded latches at sides that latched under that angle, used 4 latches for each section so the rear section could be removed or both.

First decide if you want the top flush or if you want the top to rest on top of bed sides, back, front. The 2x2 frame work underneath will be under the 3/4 plywood.

As I recall, they were strong enough to walk on after adding the 2x2s framework underneath .... glued and screwed in place to the plywood. Use waterproof glue too.

Took the sections to a local upholstery shop and had it covered with thin padded marine grade vinyl. You could easily cover the parts with thin diamond plate aluminum though.

To open or remove, open tailgate and reach underneath to pull latches. You could rig cables through small pulleys to pull the latches without crawling up in the bed underneath to reach the front ones. Trucks these days have locking TGs so anything in there is reasonable secured if desired.

 

I prefer using an aftermarket tonneau though making a custom one sounds like a good plan. Keep us posted if you decided to make your own cover.

 

Sounds like you made that cover pretty legit with getting it vinyl covered and everything. That was a great idea! I think if I go that route I'd want it to sit on top of the bed rails so it could hold more weight with the chance of having things on top of it during driving. This project might be awhile til getting to do it but it'd be great to get it done with some of the Diamondback ones going over $1,000

 

Back in them days .... most bed covers were DIY projects or you farmed it out to a shop, wasn't like today j"just go buy it" done.

Oh, and it's very "doable" for a good bit under $1000 and you can easily add a couple center braces and have it strong enough to stand on to watch the mud bogs, etc ..... whatever you want. If you are gonna put stuff on it or stand on it, you can add recessed tie downs like three on a side or bed rails along the sides ... and plate it with the thinner diamond plate aluminum .... or ..... when done, take it and have it covered by "Line-X".

I seriously considered making mine for my '07 FX4 F-side but I caught the Undercover on a good sale and it's pebble grain, it can be walked on. It is easy to clean and easy to remove and I was in a hurry.

If you do it .... PICS are requested here!

 

This is what (and why) I did on my Mark LT.

https://www.ford-trucks.com/forums/8...bed-cover.html

https://www.ford-trucks.com/forums/1...eau-cover.html