Aluminum DIY Tonneau

Dutch said:

I have made a permanent manual tonneau That is a fraction of the cost and I believe more durable than what is offered by Rivian. I had my local metal shop make 5 panels with black 0.04 aluminum in the shape of channels. 4 10.5 x 0.5 x54.5 " OD channels and 1 10 5/8 x 0.5 x 54.5 " OD channel. These were supported by 1/2 x 1/2 x 54.5 " square aluminum rods that were placed in each inside corner of the channels and were then riveted with pop rivets at the side of the channels. These panels were separated by "Auto & Marine Rubber Weatherseal". I used 2 straps connected to the forward panel to pull them out and velcro'd the straps to the underside of the panels to keep them out of the way. All total, the cost was less than $700. It is waterproof except for at the gate and secure when the gate is locked.

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Dutch said:

I have made a permanent manual tonneau That is a fraction of the cost and I believe more durable than what is offered by Rivian. I had my local metal shop make 5 panels with black 0.04 aluminum in the shape of channels. 4 10.5 x 0.5 x54.5 " OD channels and 1 10 5/8 x 0.5 x 54.5 " OD channel. These were supported by 1/2 x 1/2 x 54.5 " square aluminum rods that were placed in each inside corner of the channels and were then riveted with pop rivets at the side of the channels. These panels were separated by "Auto & Marine Rubber Weatherseal". I used 2 straps connected to the forward panel to pull them out and velcro'd the straps to the underside of the panels to keep them out of the way. All total, the cost was less than $700. It is waterproof except for at the gate and secure when the gate is locked.

Click to expand...

COdogman said:

Nice job! Looks very durable!

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Dutch said:

I have made a permanent manual tonneau That is a fraction of the cost and I believe more durable than what is offered by Rivian. I had my local metal shop make 5 panels with black 0.04 aluminum in the shape of channels. 4 10.5 x 0.5 x54.5 " OD channels and 1 10 5/8 x 0.5 x 54.5 " OD channel. These were supported by 1/2 x 1/2 x 54.5 " square aluminum rods that were placed in each inside corner of the channels and were then riveted with pop rivets at the side of the channels. These panels were separated by "Auto & Marine Rubber Weatherseal". I used 2 straps connected to the forward panel to pull them out and velcro'd the straps to the underside of the panels to keep them out of the way. All total, the cost was less than $700. It is waterproof except for at the gate and secure when the gate is locked.

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jebinc said:

Will the black finish scratch up from the repeated handling and stacking/storage? If not, how is that prevented?

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JGard18 said:

What kind of config did your truck have? Ie, was it originally built for a powered tonneau, manual tonneau, or none? My truck has a powered (well, in theory) and at this point I'm tempted to do something like this, but I'm not sure if it'll work because the tracks don't open at the tailgate.

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Dutch said:

I have made a permanent manual tonneau That is a fraction of the cost and I believe more durable than what is offered by Rivian. I had my local metal shop make 5 panels with black 0.04 aluminum in the shape of channels. 4 10.5 x 0.5 x54.5 " OD channels and 1 10 5/8 x 0.5 x 54.5 " OD channel. These were supported by 1/2 x 1/2 x 54.5 " square aluminum rods that were placed in each inside corner of the channels and were then riveted with pop rivets at the side of the channels. These panels were separated by "Auto & Marine Rubber Weatherseal". I used 2 straps connected to the forward panel to pull them out and velcro'd the straps to the underside of the panels to keep them out of the way. All total, the cost was less than $700. It is waterproof except for at the gate and secure when the gate is locked.

Click to expand...

Dutch said:

I have made a permanent manual tonneau That is a fraction of the cost and I believe more durable than what is offered by Rivian. I had my local metal shop make 5 panels with black 0.04 aluminum in the shape of channels. 4 10.5 x 0.5 x54.5 " OD channels and 1 10 5/8 x 0.5 x 54.5 " OD channel. These were supported by 1/2 x 1/2 x 54.5 " square aluminum rods that were placed in each inside corner of the channels and were then riveted with pop rivets at the side of the channels. These panels were separated by "Auto & Marine Rubber Weatherseal". I used 2 straps connected to the forward panel to pull them out and velcro'd the straps to the underside of the panels to keep them out of the way. All total, the cost was less than $700. It is waterproof except for at the gate and secure when the gate is locked.

Click to expand...