How To Modify Tonneau Cover for Tool Box Fitting

How To Modify Tonneau Cover for Tool Box Fitting

Most tonneau covers have standard designs and features custom-made for wrapping up pickup truck beds. The standard model and styling of tonneau covers make them unfitting for small truck beds or toolboxes. Although it’s not impossible to install one on your toolbox, you’d have to customize an existing tonneau cover to your toolbox styling. Check out these tricks to professionally modify tonneau cover for tool box fitting.

Tonneau covers are engineered with exclusive features to cover truck beds of different sizes and styles. They’re personalized to protect your tools and supplies from extreme weather and annoying glares. They also prevent stored items from flying out while maximizing your truck’s fuel efficiency.

Tonneau Cover That Works With Tool Box

As stated earlier, tonneau covers come in standard sizes, and for you to install one onto your toolbox, you’d need to modify them. You can customize any of these standard size tonneau covers to your toolbox styling and personal liking.

However, if you aren’t in the mood for a do-it-yourself job, there is actually a tonneau cover that is already designed to fit a truck tool box. It’s called the ACCESS Toolbox Edition Tonneau Cover, and you can check it out in this video:

Roll-Up Covers

Roll-up covers open up at the truck back, providing access to the truck bed or toolbox. They use tongue-and-groove, Velcro, or snap locking mechanisms to keep the bed locked and prevent entry or fly out of stored tools. Roll-up covers are cheap and user-friendly, but not solid and reliable enough.

Painted Metal covers

Painted metal covers complement virtually any truck bed or toolbox color or style. They’re available in multiple color options to suit any truck or toolbox decor.

Soft Folding Covers

Soft folding covers have aluminum framework highlighted by soft layering and flexible vinyl elongated over 4 or 3 sections. The sections are hinged together, and they fold flat, while the vinyl layer cover stretches out into a solid unbroken sheet once you close the cover.

Soft folding tonneau covers are user-friendly and highly flexible. They’re soft and lightweight, as well.

Hard Folding Covers

You can modify hard folding covers to fit your toolboxes. Hard folding covers have hardened tops made of aluminum. The cover tops are solid enough to hold virtually any tool and equipment type.

These types of tonneau covers are highly resistant to accidental scratches and bumps. They’re a bit more durable and user-friendly. However, hard folding covers are a bit costly.

Heavy Duty Covers

Akin to hard folding covers, heavy-duty tonneau covers have solid covers capable of bearing heavy cargos. They neither break, dent, nor rip when exposed to weighty cargos. If you’re planning to use your truck’s bed or toolbox cover to store additional load, it’d be good you buy heavy-duty tonneau covers.

Heavy-duty covers cost more than hard folding covers. But considering their superior durability and versatility, the higher price is worth it.

Retractable Covers

Retractable tonneau covers are the most versatile and flexible choices available. They have got a small housing unit that rolls in and holds the cover once it’s opened. They offer an optimal view to the rear window once folded.

These covers standstill during strong winds, which makes them a superior alternative to hardcovers.

When it comes to dealing in toolboxes, two companies stand out – UWS and Weatherguard. Having difficulty choosing which company renders better services, you can check out our post on UWS vs Weatherguard.

How to Modify Tonneau Cover for Tool Box Fitting

Fitting any of the standard sized tonneau covers we mentioned above onto your toolbox isn’t impossible. It won’t be a smooth walk in the park, though. However, if you know the bolts and nuts of the entire exercise, you’ll find it fun and easy. Let’s take a walk through the process of modifying tonneau covers for toolboxes.

What You Need

  • Two Bungie cords
  • Tape measure
  • Local upholstery shop or sewing machine
  • Razorblade
  • Drill and bits of sizes 11/64
  • Sharpie
  • Tape measure
  • Hacksaw
  • Straight edge

How Long Will the Project Take to Complete?

It will take you around two to three hours to get everything done and working.

The Installation Guidelines—the Nitty-Gritties

  1. Take new tonneau cover measurements based on the size of your toolbox.
  2. Mark around ½ foot on the front of the second bar. Measure the middle bar towards the cab. While taking the measurements, ensure the tonneau cover is rolled up.
  3. Once done taking the measurements, use the hacksaw to cut it to size.
  4. Connect the two halves to achieve your desired length. It will entirely depend on the size or brand of the toolbox. Some halves will extend about ½ foot behind the first bar.
  5. Now, cut short the overlapping area. The cut size will be the new tonneau’s size.
  6. Before you go ahead, test the fitting ability of the tonneau cover onto your toolbox.
  7. Remove the tonneau cover. Unroll it upside down and make a mark a foot away from the cut edge on both the passenger and driver side. There is no specific order to follow, but you must ensure you mark each of them.
  8. Use a straight edge to link the two marks through the tonneau covering. Once done, cut out the sections. The added inch provides room for errors when you’re sewing.
  9. It’s time to sew your tonneau. If you don’t have a sewing machine, you’d rather get it stitched in a local upholstery shop.
  10. Place the two halves of the cover top in line with the cut ends. Doing so will ensure that the cover opens like a book.
  11. Once you’re done, drill out the tonneau frame so you can hook the Bungie through it. Ensure you don’t drill through the cover. You can link the other end of the tonneau via the bracket, so the flap is held at highway speed.

How to Modify Tonneau Cover for Tool Box Fitting – Conclusion

Tonneau covers for trucks come in multiple styles and designs. Whichever cover design or style you select, ensure it has the features and functions to match your toolbox design and styling. Look for a tonneau cover that has dimensions close to your toolbox’s measurements.

Also, ensure the tonneau cover you select will fit well into the mounting hardware, brackets, and rails of the toolbox. Its design, functions, and features should match your toolbox’s contours, stake holes, and hooks.

Use the above guide on how to modify tonneau cover for tool box fitting so you can wrap up your toolbox to your liking as well as add to its protective layers. And again, if you are looking for the easy way out, check out the ACCESS Tool Box Edition Roll-Up Tonneau Cover to make the job easy.

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