How To Make Custom Tonneau Cover? 6 Step By Step Guide

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Written By Waylon Joe

Hey, It’s Waylon “Joe” Kite here. I am a West Virginia native and a die-hard pickup truck fan. My story with trucks started with my dad’s 1989 Ford F-150, and it's still going on. I'll share all my trucking experiences (both great and gross ones) with you. I have a garage full of tools to fix and renovate trucks and a freezer full of ales. Do you want to join me?

A tonneau cover is a great way to keep your truck bed safe and secure. But if you can’t find the right cover for your truck, you can always make your own!

In this article, we’ll show you how to make a custom tonneau cover for your vehicle. It’s easy and affordable, and it will keep your truck bed protected from the elements.

How To Make Custom Tonneau Cover?

You can make a custom tonneau cover for your truck. By using the right tools and some creativity, you can create a functional and stylish cover.

How To Make Custom Tonneau Cover

However, if you want to make a custom tonneau cover, it is essential to consider what you will use it for. If you want to keep your truck bed safe from the elements, you can use a simple tarp or even a piece of plywood.

However, if you want to use your truck bed for hauling cargo, you will need to create a sturdier cover. Below we will give you how to make a hard tonneau cover.

There are a few things that you will need to make a custom tonneau cover:

  • Two sheets of 1/2 inch plywood. This could be different depending on your bed size
  • 5 meters of vinyl fabric
  • Six pieces of 1×2’’
  • A Drill
  • The Screws
  • Table saw
  • Black paint
  • Contact glue
  • Spray glue
  • Stapler
  • One piano hinge

If you collect all these supplies, you are ready to make a custom tonneau cover for your truck!

Step 1: Cut the Plywood

The first step is to cut the plywood into two pieces. Two pieces should be the same size as your truck bed.

Keep in mind that these two pieces will be your truck cover, so they must overlap the bedsides. To cut it, first, measure your car’s shape, then follow the measurements and cut them.

>> Should I Put A Tonneau Cover On My Truck?

Step 2: Make A Fram

Use the 1×2’’ to make a frame around the edge of the smaller piece of plywood. This will give the cover more stability and strength.

Both frames should fit in the bed borders with approximately 1cm of clearance to the duraliner. Make sure that the frame is snug against the plywood, and use screws to secure it in place.

Step 3: Paint the Frame and the plywood

Use black paint or any other color of your choice to cover the frame and plywood. This will give the cover a more finished look and help protect it from the elements.

Step 4: Wrap the Plywood in Fabric

Now it’s time to wrap the plywood in fabric. This will give the cover a softer look and feel, and it will also help to protect the wood from moisture.

Use contact glue or spray glue to attach the fabric to the plywood. Start at one end and work your way around, making sure that the fabric is tight and smooth. Once the fabric is in place, use a stapler to secure it along the edges.

>> Can You Put A Tonneau Cover On A Truck With Bed Rails?

Step 5: Attach the Hinges

Use screws to attach the hinges to the edge of the cover. Please make sure that the hinges are aligned so that they will open and close quickly.

Step 6: Install the Cover

Now it’s time to install the cover on your truck. Place the cover over the bed of your vehicle and align the hinges with the bed rails. Once the hinges are in place, use screws to secure them to the bed rails.

And that’s it! You’ve now created a custom tonneau cover for your truck. This cover will protect your bed from the elements and keep your cargo safe and secure.

Pros and cons of Tonneau Covers?

There are a few key advantages and disadvantages to consider when thinking about purchasing a tonneau cover for your truck.

Pros of Tonneau Covers?

  1. They protect your cargo from weather conditions and potential theft.
  2. It can improve your fuel economy.
  3. Easy to install and remove.
  4. Many different styles to choose from to suit your needs.
  5. Fairly low-cost investment.

Cons of Tonneau Covers?

  1. If not correctly installed, they can cause wind noise.
  2. Some may be difficult to open and close.
  3. It needs to be removed for large loads.
  4. Not 100% effective in preventing theft.
  5. It can be damaged by hail or other debris.

Ultimately, the decision of whether or not to get a tonneau cover is up to the individual and what their specific needs are.

There are a number of high-quality options on the market that can provide great protection for your cargo while still remaining easy to use.

If you frequently haul large loads or live in an area with a lot of hail or debris, you may want to reconsider getting a cover. Otherwise, a tonneau cover can be a great investment for your truck.


How Do You Cut A Tonneau Cover For Your Truck?

To cut a tonneau cover, you will need to use a table saw. First, measure the shape of your truck bed and cut the plywood accordingly. Next, use the 1×2¨ to make a frame around the edge of the smaller piece of plywood.

Are Tonneau Covers Supposed To Be Waterproof?

The answer to this question largely depends on the specific tonneau cover you have. Many tonneau covers are designed to be water-resistant but not necessarily waterproof.
If you are concerned about keeping your cargo area completely dry, you may want to invest in a cover that is specifically marketed as being waterproof.

Can I Go Through A Carwash With A Custom Tonneau Cover?

Yes – you can take a Custom cover through a carwash. However, we recommend that you use a touchless carwash, as the brushes on some automated car washes can damage your cover.
It’s always best to discuss with an expert for your specific coverage to know if there are any washing instructions that need to be followed.

Final Thoughts

We hope that this guide has been helpful in teaching you how to measure, cut, and install a custom tonneau cover for your truck. This process is relatively straightforward and can be completed in a few hours.

Read also: Can You Go Through A Carwash With A Tonneau Cover?

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