Aluminum DIY Tonneau

[Dutch]

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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[COdogman]

Nice job! Looks very durable!

 

[Donald Stanfield]

I bet the likelihood of one of those corners chipping off is quite a bit smaller than the one Rivian is offering and this costs 700 dollars for a one off. So for 1800 the Rivian one isn't doing so hot.

 

[agame32]

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.

Good job by you!

 

[Dutch]

I forgot to mention I stuck 1/2" sheet of insulation to the underside of each panel with Loctite professional adhesive spray.

 

[jebinc]

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.

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

 

[mini2nut]

Great job, looks like an OEM bed cover.

Thanks for sharing with forum members.

 

[403Wyn]

Nice job! Looks very durable!

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.

Looks great! And it was a great idea supporting a local business to do the metal work. I bought the interrobang cover about a month ago and I’m happy with it. The cost was $1300. Looks similar to your cover. It’s not watertight but it does a decent job of keeping the water out. I don’t like having to remove the panels because they scratch when they rub against each other in the storage bag. I use a snowboard bag and stow it in the gear tunnel.

 

[JGard18]

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.

 

[JCBAZ]

Very impressive! I have a metal guy that I will show this to and see if he can duplicate. If anyone is in the Phoenix area and interested, let me know and making more than one may help price point and his motivation to custom make these.

 

[Dutch]

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

I guess it would. I had thought of making a bag for it. Wrapping it in a old blanket would protect it as well.

 

[Dutch]

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.

The truck was set up for a manual tonneau. with the tracks opening at the tail end.

 

[Fclmd]

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.

Very nice!

 

[Ripped]

It looks nice, I am awaiting more reviews of the factory supplied tonneau, and if I do not opt for an aftermarket trifold, I may just make my own too, although I am thinking carbon fibre and carbon core PVC foam, as I liked to be fairly abusive of my current bed cover. Then I could probably walk on it if I wanted.

Plus if I glassed my own, I could incorporate tie-offs and custom touches.

 

[Brad Rasmussen]

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.

Is that wood inside the aluminum rods? If so, likely added to provide a bit more support across the span?

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