14N Posted August 9, 2012 Share Posted August 9, 2012 I know this has been done (probably many times) before, but I thought I’d share my DIY tonneau cover as a bit of a ‘how to’ just in case anyone else fancies trying it. I guess there are a few ways you can tackle this, but this is how I did mine. First you need a template of the OEM tonneau. Either trace round a mates or get a friendly forum member to trace theirs and stick it in the post (cheers Dave P). You’ll need two of the dividers, as you’re gonna stick them together later. I used 6mm MDF. Once you’ve cut out your two MDF dividers (and test fitted them in your car), you may have a piece of MDF spare. I used this to make the ‘Z’ logo. I found an image of the ‘Z’ and just enlarged it then printed it out and used it as a template. Then measure the centre of one of the dividers and mark where you’d like the ‘Z’ to go. Spray some spray adhesive onto your logo and mount it to one of the dividers. Originally I was going to fit a ‘Z’ to both sides of the divider, but it can’t really be seen that well from the boot side, so I just opted for the one. Now you’re going to cover one side of each of the two dividers you’ve cut out of MDF with acoustic carpet (I got mine from eBay). Spray plenty of spray adhesive and leave it for a minute – it gets tackier as the solvents dissolve. With the divider that has the ‘Z’ mounted, sprays LOTS of adhesive on and around the edges of the ‘Z’ (you want to make sure it sticks). Then mount the acoustic carpet to the ‘Z’ first, using your finger tip to push it into all the edges of the logo. Then continue to mount the acoustic carpet as normal (it’s quite elastic, so you should still easily get a flat finish around the ‘Z’. OK, so now you’ve cut out your dividers, cut a ‘Z’ logo, mounted the logo and covered both pieces with acoustic carpet? Now you just need to glue both sides together and fit it in your Zed. When gluing both sides together, spray BOTH inside sides and remember to let the adhesive settle for a minute of two. It really is strong stuff – especially when applied to both surfaces. Fitting is simply a case of ‘wedging’ your new divider into position. If you’ve cut the MDF to the right size/shape, the acoustic carpet will help hold it in position. Don't panic if when you first fit it, it just falls through under the strut brace, the opening varies in width so just try moving the divider's position. When you’re done, hopefully your vertical tonneau will look like this: Quote Link to comment Share on other sites More sharing options...
buster Posted August 9, 2012 Share Posted August 9, 2012 well done m8 looks Quote Link to comment Share on other sites More sharing options...
Dblock Posted August 9, 2012 Share Posted August 9, 2012 I like that. Simple yet effective. Quote Link to comment Share on other sites More sharing options...
Topcat Posted August 9, 2012 Share Posted August 9, 2012 Good work, looks professional! Quote Link to comment Share on other sites More sharing options...
nij1983 Posted August 9, 2012 Share Posted August 9, 2012 nicely done Quote Link to comment Share on other sites More sharing options...
KyleR Posted August 10, 2012 Share Posted August 10, 2012 Looks great mate, and you make it sound so easy Quote Link to comment Share on other sites More sharing options...
DoogyRev Posted August 10, 2012 Share Posted August 10, 2012 Nice touch with the "Z" Quote Link to comment Share on other sites More sharing options...
daveparkin Posted August 10, 2012 Share Posted August 10, 2012 That looks great mate - especially like the Z on it Quote Link to comment Share on other sites More sharing options...
14N Posted August 13, 2012 Author Share Posted August 13, 2012 Cheers guys, appreciate the comments Quote Link to comment Share on other sites More sharing options...
M13KYF Posted August 13, 2012 Share Posted August 13, 2012 nice work Quote Link to comment Share on other sites More sharing options...
14N Posted August 20, 2012 Author Share Posted August 20, 2012 Just a further lesson learned from my 2nd attempt... Instead of cutting out 2 seperate shapes for the tonneau from MDF, cut your sheet of MDF in half lengthways first, then screw the 2 halves together. This way you'll only need to cut out 1 tonneau shape (albeit double thicklness) and it will ensure both sides are the same size and shape. In my first attempt, I cut them out seperately and the 2 sides were a bit, erm, 'different' as I'm rubbish with a jigsaw! Quote Link to comment Share on other sites More sharing options...
Doug86 Posted August 21, 2012 Share Posted August 21, 2012 Could you send me the template in the post? Quote Link to comment Share on other sites More sharing options...
TomS Posted August 21, 2012 Share Posted August 21, 2012 Looks really good, will definitely try this one weekend! Quote Link to comment Share on other sites More sharing options...
ersen.o Posted August 22, 2012 Share Posted August 22, 2012 i wouldn't mind a template in the post too please Quote Link to comment Share on other sites More sharing options...
glrnet Posted August 22, 2012 Share Posted August 22, 2012 Nice one Ian Now, that's given me an idea Quote Link to comment Share on other sites More sharing options...
14N Posted August 22, 2012 Author Share Posted August 22, 2012 Thanks all. Ersen and Doug, I'll drop you a PM when I'm next on the laptop. Glr, they do silver and blue acoustic carpet too... Quote Link to comment Share on other sites More sharing options...
glrnet Posted August 22, 2012 Share Posted August 22, 2012 Never a truer word spoken in jest Thanks all. Ersen and Doug, I'll drop you a PM when I'm next on the laptop. Glr, they do silver and blue acoustic carpet too... Quote Link to comment Share on other sites More sharing options...
14N Posted August 23, 2012 Author Share Posted August 23, 2012 Never a truer word spoken in jest I was serious mate I saw (and drooled over, sorry) your car in Wales. Definitely got the blue and silver vibe Maybe do one side of the divider blue, the other silver. Then you can swap it round. Aww man, now you've got me thinking.... Quote Link to comment Share on other sites More sharing options...
hawker1986 Posted August 29, 2012 Share Posted August 29, 2012 Hi all, Just wanted to give Ian some official thanks, following his guide I was taken with the inspiration and have made my own tonneau cover as per the guide . Also he deserves much thanks for sending me the templates out of his own pocket. Heres a token crappy camera phone shot...I was too excited to get it in place to take pictures at the time :S. Many thanks Ian, really appreciate it. Hawker Quote Link to comment Share on other sites More sharing options...
14N Posted August 30, 2012 Author Share Posted August 30, 2012 No worries Hawker. Thanks for the thanks. I'm glad you found the guide useful and inspirational Looks good BTW Quote Link to comment Share on other sites More sharing options...
ChrisS Posted August 30, 2012 Share Posted August 30, 2012 Moved to 'Guides' (because Ian has made lots of people very happy) Quote Link to comment Share on other sites More sharing options...
SX Dave Posted November 22, 2012 Share Posted November 22, 2012 Would anyone be able to send me a template please? Really like the look of this and i dont think "making" a template from scratch would be that easy. Or anyone close enough to Thurrock Essex i could visit to trace a template? thanks Dave Quote Link to comment Share on other sites More sharing options...
rodgeevans Posted November 22, 2012 Share Posted November 22, 2012 Is it possible to upload the template as a pdf and attach to this guide. I could do it if someone sends me the template makes it alot easier for others to make Quote Link to comment Share on other sites More sharing options...
oderuyter Posted December 31, 2013 Share Posted December 31, 2013 Hey Lovely people of the interwebs, is there anyone amazing that could send me the template please, I would like to have a shot at this Quote Link to comment Share on other sites More sharing options...
ioneabee Posted December 31, 2013 Share Posted December 31, 2013 well - since Ian has made this into a small business...........I doubt it Quote Link to comment Share on other sites More sharing options...
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