Homemade metal box cover

[ToddTheCanadian]

So I got my ranger last fall, and was looking at the hard tonneau covers (like the diamondback covers) and they cost a fortune. (I am in Canada and the cost is amplified here by exchange rates, exorbitant shipping, and duties). So I decided that I would try to make my own.
It's been an interesting adventure designing and building this thing. I'm generally satisfied with the end product, but would definitely make some big changes if I were to do it again.
(That's how these things always go).

I did some sloppy book keeping, but I'm pretty sure I got this done for about half the cost of a diamondback cover. That includes having some parts laser cut at a steel shop, and having the whole thing powder coated. It does NOT include my time though

Now that I have it done, I have so many ideas for another one, I kind of want to make a new one, but I've got too many other projects on the list.

I installed it this morning and drove around for about an hour, and I'm thrilled that the whole thing is dead silent. I was afraid the latch mechanism would clink around, or there would be wind-noise, but nope - zero noise
(Things that rattle or clink around while you're driving - drive me crazy).

The main frame/structure is made out of steel. The side rails are 1/8" steel, the end pieces are 3/16" steel. The lids are made out of 1/8" aluminum checker plate. The whole thing is powder coated.

(Truck is filthy, I know..)
Here is the finished product:

I used lift-off hinges on the lids, so each lid could be removed in about a minute (just unclip the gas struts and the lid slides off with no tools).

1/4" steel rod for the locking mechanism.

I added M8 stainless steel riv-nuts to the side rails so that I could bolt a platform, ladder rack (or anything else) straddling the whole thing without necessarily interfering with the lids.

Here are some misc pictures from the build itself in no particular order:

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[Msfitoy]

You're one heck of a metal fabricator! Very nice work...

 

[LaBalbe]

Looks great! I like that the panels open out to the side; that seems to be easier to work with than the Diamondback "front & back" approach, although I get why they do it that way, too.

 

[Joeiconic]

How much does it weigh if you need to take it off to haul something?

 

[Danager]

That’s pretty good work. It’s nice to have skills that save money AND get you what you want.
If I tried that, it would look a lot like a tuna can being held in place by one small section, holding on for dear life.

 

[ToddTheCanadian]

How much does it weigh if you need to take it off to haul something?

My 14yr old son and I easily picked it up by the side rails to move it off the saw horses and put it on the truck. It wouldn't be light to move for one person, but it would definitely be possible. The biggest problem would be the dimensions. It's awkward to move because of it's size.

I used marine lift off hinges for the lids, so worse case scenario if I wanted to take it off by myself, I could unclip the struts and take each lid off. If you open the lids to 90deg, they can slide off backwards with no tools. This takes about a minute per lid.

The frame itself without the lids on it can be lifted out with one hand no problem.

 

[ToddTheCanadian]

That’s pretty good work. It’s nice to have skills that save money AND get you what you want.
If I tried that, it would look a lot like a tuna can being held in place by one small section, holding on for dear life.

My skills are tenacity and perseverance. It's surprising how far they will take you. (sometimes in the wrong direction, but dammit you'll get there).

 

[got3fords]

That's pretty damn slick! About how much does it weigh?

 

[Forever Blue]

Well done

 

[Buckbull]

Your fabricating skills are legit. Love the design.

 

[ToddTheCanadian]

That's pretty damn slick! About how much does it weigh?

I'm sorry, but I'm really not confident in my ability to estimate the weight. I answered another question in here about the weight. I can say that the lids weigh about 40lbs each. The frame without the lids isn't very heavy.

 

[5thranger]

So I got my ranger last fall, and was looking at the hard tonneau covers (like the diamondback covers) and they cost a fortune. (I am in Canada and the cost is amplified here by exchange rates, exorbitant shipping, and duties). So I decided that I would try to make my own.
It's been an interesting adventure designing and building this thing. I'm generally satisfied with the end product, but would definitely make some big changes if I were to do it again.
(That's how these things always go).

I did some sloppy book keeping, but I'm pretty sure I got this done for about half the cost of a diamondback cover. That includes having some parts laser cut at a steel shop, and having the whole thing powder coated. It does NOT include my time though

Now that I have it done, I have so many ideas for another one, I kind of want to make a new one, but I've got too many other projects on the list.

I installed it this morning and drove around for about an hour, and I'm thrilled that the whole thing is dead silent. I was afraid the latch mechanism would clink around, or there would be wind-noise, but nope - zero noise
(Things that rattle or clink around while you're driving - drive me crazy).

The main frame/structure is made out of steel. The side rails are 1/8" steel, the end pieces are 3/16" steel. The lids are made out of 1/8" aluminum checker plate. The whole thing is powder coated.

(Truck is filthy, I know..)
Here is the finished product:

I used lift-off hinges on the lids, so each lid could be removed in about a minute (just unclip the gas struts and the lid slides off with no tools).

1/4" steel rod for the locking mechanism.

I added M8 stainless steel riv-nuts to the side rails so that I could bolt a platform, ladder rack (or anything else) straddling the whole thing without necessarily interfering with the lids.

Here are some misc pictures from the build itself in no particular order:

I did not see a patent number so I took the liberty of using your drawings and securing one for myself. Just kidding, you should get patent protection however. Very nice design.

 

[got3fords]

I'm sorry, but I'm really not confident in my ability to estimate the weight. I answered another question in here about the weight. I can say that the lids weigh about 40lbs each. The frame without the lids isn't very heavy.

I was just curious, I am always careful about unnecessary weight. So I am guessing your rig is about 100lbs.?

 

[ToddTheCanadian]

I was just curious, I am always careful about unnecessary weight. So I am guessing your rig is about 100lbs.?

Yeah, I think that's a pretty fair estimate.

 

[ToddTheCanadian]

I did not see a patent number so I took the liberty of using your drawings and securing one for myself. Just kidding, you should get patent protection however. Very nice design.

Lol, help yourself, just lmk if you want a higher res version
I am definitely satisfied with the result, but if I were to do it again, I think would make v2 differently.

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