Aluminum tonneau cover - The 1947 - Present Chevrolet & GMC Truck Message Board Network

mikep · 02-21-2003, 10:42 PM

I'm thinking about building a tonneau cover for my '68. What I was considering is welding a framework from 1 inch square aluminum tubing and then skinning the top with 20 gage aluminum sheeting and then finishing and painting it body color. Anyone done this? I could mount hinges on the front and have it one piece or maybe on the sides and have it lift in the center as a 2 piece unit.

70c10 · 02-21-2003, 10:48 PM

Mike that sounds like alot of work but very cool!. The aluminum would be light AND durable. I didn't realize you could buy a sheet that big. That might also look good polished then clearcoated for protection. Go for it!........Jim

mikep · 02-21-2003, 11:06 PM

Theres a little company called Boeing that resides not far from where I live that often has large sheets of thin gauge aluminum in their surplus store . I dont think it would take that much to get together. a few hours setup and welding. Ive got a TIG .

weasel29gm · 02-21-2003, 11:25 PM

Hey Mike, I was talkin to a guy at work today about that. My idea was a lightweight frame and use a thin hardwood. I know it would heavy but hinge it half way and use small air shocks to raise it. My thoughts on the wood was that new snap lock flooring and seal it and wax it good. Any thoughts?

mikep · 02-21-2003, 11:38 PM

It might work where your'e at but it wouldnt work here. too much water in the winter time. It'd turn into a moldy mushroom growing pile of mush in less than 3 seasons.

weasel29gm · 02-22-2003, 12:02 AM

How does wood bed floors hold up. I thought if it was sealed good it would hold. My 69 won't be a daily driver, btw I like your idea that would be sharp!!!

mikep · 02-22-2003, 12:14 AM

Ive never seen one that wasnt rotten out in this climate. It rains a lot and the temperature is just right for fungal growth. Like I said if your in west virginia it would probably hold up but all the wood beds Ive seen in westen washington were rotted out. Not to say there arent some nice wood beds around here but I doubt they are kept out in th weather.

'72 Shorty · 02-22-2003, 03:54 AM

I'm thinking about doing something similar on mine since hard tonneaus are so expensive for stepsides. I really need to get the wood bed out of the weather, this re-finish every 3 weeks is geting old fast. I think I've put over 100 coats of oil down.

I like the idea of aluminum, the problem is I don't have a tig to weld it, I was thinking about building one out of fiberglass and painting it body color. Of course, a project like this is the perfect excuse to finally buy a good welder

pissonNOS · 02-22-2003, 12:19 PM

seal ur bed with MINWAX all season clear coat i only have to redo my bed once a year and it lasts me thru the winter with snow on it all the time (daily driver)

mikep · 02-22-2003, 01:03 PM

Its hard for people who dont live in a temperate rain forest to understand how destructive constant cool rain is to even well treated wood or paint that isnt constantly waxed . I'm sure they get rain a few times a month and think it cant be all that bad and that wer'e all a bunch of pansies who dont know how to deal with a little rain. Snow isnt rain! Rain washes and washes and washes and penetrates . Ive seen it rain nonstop from November to March. Thats every minute of every day in non El Nino years . Even the best wood sealer is gone in a few weeks in those conditions.

PanelDeland · 02-22-2003, 03:17 PM

You guys might want to check out www.checkmate.com They make hard tonnues for a lot of trucks other companies don't.They are the main ones who make flush mount hard covers also.If I remember correctly they use fibreglass and have the shocks and are a quick release hinge for easy removal if you need to haul.The last I checked they were about $400.00 for one for my Dddd odge.

70 Jimmy · 02-22-2003, 08:35 PM

Unless your running an aluminium block, your truck is light in the rear anyway so why not use steel? They make gas struts that will handle the added wieght. Just a thought.

low 84 · 02-22-2003, 09:14 PM

this is my friends. i can't remember what material he used but i can ask next time i talk to him. the closed flap is to access the fuel cell.

Ackattack · 02-23-2003, 01:59 AM

will that thin guage aluminum warp when you weld it? I've thought of doing the same thing, but was worried about warpage.

mikep · 02-23-2003, 02:07 AM

I wouldnt do full length welds or even long beads. I was thinking of drilling holes along the length of the aluminum support beams and then plug welding the sheeting to the supports. That should keep warpage to a minumum . Since I'd be painting it anyway I'll need to do some bodywork and a little filling so slight warpage isnt much of a problem.

02-21-2003, 10:42 PM	#1
mikep Used to have a truck Join Date: May 2002 Location: port orchard WA Posts: 1,552	Aluminum tonneau cover I'm thinking about building a tonneau cover for my '68. What I was considering is welding a framework from 1 inch square aluminum tubing and then skinning the top with 20 gage aluminum sheeting and then finishing and painting it body color. Anyone done this? I could mount hinges on the front and have it one piece or maybe on the sides and have it lift in the center as a 2 piece unit. __________________ No truck :-(

02-21-2003, 10:48 PM	#2
70c10 67-72 Addict! Join Date: Feb 2002 Location: The TAX State! Posts: 7,857	Mike that sounds like alot of work but very cool!. The aluminum would be light AND durable. I didn't realize you could buy a sheet that big. That might also look good polished then clearcoated for protection. Go for it!........Jim __________________ Jim 1970 C/10 Fleetside w/Ghost Flames Lowered 4.5" front and 4" rear (Raked) 355/350 Turbo w/shift kit 10" Redneck Performance Verter w/2500 stall Hooker Super Comps part#2808-1 Performer RPM Air-Gap 12 Bolt w/3:73 gears- Eaton Posi Comp Cams XE262 with 1.6 Crane Energizers, Road Demon 625 and Brodix IK 180 heads

02-21-2003, 11:06 PM	#3
mikep Used to have a truck Join Date: May 2002 Location: port orchard WA Posts: 1,552	Theres a little company called Boeing that resides not far from where I live that often has large sheets of thin gauge aluminum in their surplus store . I dont think it would take that much to get together. a few hours setup and welding. Ive got a TIG . __________________ No truck :-(

02-21-2003, 11:25 PM	#4
weasel29gm SLOW BUT SURE,BUT CLOSER Join Date: Feb 2002 Location: eleanor wv usa Posts: 3,094	Hey Mike, I was talkin to a guy at work today about that. My idea was a lightweight frame and use a thin hardwood. I know it would heavy but hinge it half way and use small air shocks to raise it. My thoughts on the wood was that new snap lock flooring and seal it and wax it good. Any thoughts? __________________ 69 C-10, OWNED 38YRS... 350 over 30, 350 Turbo, 3:73 Posi P/S, P/B Black with red and black int. ''LOVE THESE OLD ''TRUCKS.......

02-21-2003, 11:38 PM	#5
mikep Used to have a truck Join Date: May 2002 Location: port orchard WA Posts: 1,552	It might work where your'e at but it wouldnt work here. too much water in the winter time. It'd turn into a moldy mushroom growing pile of mush in less than 3 seasons. __________________ No truck :-(

02-22-2003, 12:02 AM	#6
weasel29gm SLOW BUT SURE,BUT CLOSER Join Date: Feb 2002 Location: eleanor wv usa Posts: 3,094	How does wood bed floors hold up. I thought if it was sealed good it would hold. My 69 won't be a daily driver, btw I like your idea that would be sharp!!! __________________ 69 C-10, OWNED 38YRS... 350 over 30, 350 Turbo, 3:73 Posi P/S, P/B Black with red and black int. ''LOVE THESE OLD ''TRUCKS.......

02-22-2003, 12:14 AM	#7
mikep Used to have a truck Join Date: May 2002 Location: port orchard WA Posts: 1,552	Ive never seen one that wasnt rotten out in this climate. It rains a lot and the temperature is just right for fungal growth. Like I said if your in west virginia it would probably hold up but all the wood beds Ive seen in westen washington were rotted out. Not to say there arent some nice wood beds around here but I doubt they are kept out in th weather. __________________ No truck :-(

02-22-2003, 03:54 AM	#8
'72 Shorty I finally got an avatar Join Date: Jan 2003 Location: Cheney, WA Posts: 180	I'm thinking about doing something similar on mine since hard tonneaus are so expensive for stepsides. I really need to get the wood bed out of the weather, this re-finish every 3 weeks is geting old fast. I think I've put over 100 coats of oil down. I like the idea of aluminum, the problem is I don't have a tig to weld it, I was thinking about building one out of fiberglass and painting it body color. Of course, a project like this is the perfect excuse to finally buy a good welder __________________ -72 C-10 short step (straight line only) 12.922/102.28 -69 C-20 on Propane (DD) -69 C-10 -56 Mack B-753LS (tow rig) -94 Chev K2500 Short Ex-Cab -89 Isuzu Trooper...Kinda -03 Kawasaki KFX-400 -05 Suzuki DRZ-400S

02-22-2003, 12:19 PM	#9
pissonNOS senior member Join Date: Feb 2003 Location: fort macleod alberta Posts: 2,770	seal ur bed with MINWAX all season clear coat i only have to redo my bed once a year and it lasts me thru the winter with snow on it all the time (daily driver) __________________ 69 GMC bagged

02-22-2003, 01:03 PM	#10
mikep Used to have a truck Join Date: May 2002 Location: port orchard WA Posts: 1,552	Its hard for people who dont live in a temperate rain forest to understand how destructive constant cool rain is to even well treated wood or paint that isnt constantly waxed . I'm sure they get rain a few times a month and think it cant be all that bad and that wer'e all a bunch of pansies who dont know how to deal with a little rain. Snow isnt rain! Rain washes and washes and washes and penetrates . Ive seen it rain nonstop from November to March. Thats every minute of every day in non El Nino years . Even the best wood sealer is gone in a few weeks in those conditions. __________________ No truck :-(

02-22-2003, 03:17 PM	#11
PanelDeland I am a Referee of life. Join Date: Jun 2000 Location: Greensboro N.C. Posts: 13,993	You guys might want to check out www.checkmate.com They make hard tonnues for a lot of trucks other companies don't.They are the main ones who make flush mount hard covers also.If I remember correctly they use fibreglass and have the shocks and are a quick release hinge for easy removal if you need to haul.The last I checked they were about $400.00 for one for my Dddd odge. __________________ The 47-present Chevrolet and GMC Truck Message Board Network,it's owners,moderators,members,and associates of any type should not be held responsible for my opinion. You can't fix stupid,not even with duct tape. "My appearance is due to the fact that "GOD" does punish you for having too much fun!" Barrett-Jackson has perfected alchemy,they make rust into gold! "You can lead a horse to water but you can't saddle a duck" "Cleverly disguised as a 'Responsible Adult' "Sometimes your Knight in shining armor is just a retard in tinfoil"

02-22-2003, 08:35 PM	#12
70 Jimmy aka Crusher, Crushergmc Join Date: Mar 2000 Location: Oregon Posts: 1,834	Unless your running an aluminium block, your truck is light in the rear anyway so why not use steel? They make gas struts that will handle the added wieght. Just a thought. __________________ "KEEP IT DOWN!" 70 Jimmy 454 2wd 56 GMC Big Window "It's funny till someone gets hurt, then it's freakin' hilarious"

02-22-2003, 09:14 PM	#13
low 84 Registered User Join Date: Jan 2002 Location: Houston, TX Posts: 2,144	this is my friends. i can't remember what material he used but i can ask next time i talk to him. the closed flap is to access the fuel cell. __________________ '51 F100, backhalf with a narrowed 9 and coil overs, 18.5" mickeys, monte front clip, +400" sbc in the works '05 1500 Crew Cab RIP '84 swb 5/7 drop, solid cammed 408 w/ fully ported dart heads, th350 w/ 10 inch hughes, 12 bolt w/ 3.73 richmonds and a locker '80 swb 4x4 in progress: 7" lift, 350 th350/np205, d44 and 1.5" ORD tie rod, 14BFF w/discs , armored diff covers, 40" MTR's

02-23-2003, 01:59 AM	#14
Ackattack Senior Member Join Date: Aug 2002 Location: Valley Center KS Posts: 3,525	will that thin guage aluminum warp when you weld it? I've thought of doing the same thing, but was worried about warpage. __________________ Project Bruiser: 68 Pro-Touring C-10 5.3L / 4L60E Project Ironhide: 97 GMC Crew Cab 4x4 Cummins SOLD: '69 GMC 1/2T SWB TBI'd: Project No Buck Assembly Manual Index Sign up Thread!!! Factory Service Manual Index

02-23-2003, 02:07 AM	#15
mikep Used to have a truck Join Date: May 2002 Location: port orchard WA Posts: 1,552	I wouldnt do full length welds or even long beads. I was thinking of drilling holes along the length of the aluminum support beams and then plug welding the sheeting to the supports. That should keep warpage to a minumum . Since I'd be painting it anyway I'll need to do some bodywork and a little filling so slight warpage isnt much of a problem. __________________ No truck :-(



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