Need some ideas on bed cover

[50 F1]

I am thinking I would like to build a bed cover for my truck.

What I would like to build it out of is 1/8" aluminum for the top. I have  a set of those Sashe Rod Shop hinges. Two latches,  hooked together so they will work with one opener.  A couple of heavy duty gas shocks.  Hinges on the passenger side of the box, latches on drivers side of box.

Doesn't need to be water tight. I just want it to be simple looking without a bunch of gadgets and gaskets.

Problems----   I think the 1/8" aluminum will be to heavy and it will sag from front to back without any frame work underneath.  The bed is 49" wide so that means  a 48" sheet will not work. Adding the inch would be a night mare

What about a 1" thin wall sq tubing frame work double side with 16 gauge sheet metal.  Still have the 49" problem though.

Any ideas??

My brain keeps going back to the 1 sheet of aluminum, two hinges, two latches and two gas shocks but i don't think it will work

Thanks Mike

[enjenjo]

I have built several. I use 1/2" by 1"  20 ga rectangular tubing for the frame, with a 1" square tube down the center, tapered to 1/2" about 18" on each end, so the cover has a slight arch. I install a 1/2" crossmember about every 2 ft. Hinges and latches are attached to a 16 ga formed plate in the corners. This could all be done with aluminum if you have a TIG.

I install a 1/2" by 2"wood border on the top of the frame all the way round that sets an inch or so outside the metal frame. There is some PVC foam trim that might work good for the border/tack strip. The rest of the cover is made from 1/2" foil faced rigid foam insulation screwed and glued to the frame. I then cover it with landau padding and landau vinyl, glued to the padding, and tacked on the under side of the wood border. This is covered with truck cap foam weatherstrip on the edge.

The oldest one I did has been recovered with vinyl three times now and is still going strong after more than 20 years.

[Digger]

It might take some hunting but you can get aluminum sheet wider than 48 inches. I bought a 5X10 footer a few years ago.

[Glen]

I think those look good when covered with convertible top material....commonly referred to as "stay-fast" material?  It has a suede look from a distance and wears nice.

[50 F1]

Thanks for all the info.    I put the bed cover on the back burner.  I need to focus on stuff like starting, stopping, shifting, sitting, steering etc. lol

Thanks Mike

[papastoyss]

How about narrowing the bed & tailgate enough that the 48" material would suffice?