Here's what I got from Oscar...BTW - GORGEOUS EPup!!!
Here are some basic shots of my tonneau cover project:
I didn't want to drill any holes, and commercially available units are
unheard of, since Epup's have so many curves and wierd dimensions.
Started with G1S 3/8" plywood. Used plastic / cardboard to 'carve' a
template for the swoopy corners behind the cab and at the tailgate
(lots of fiddling here). Do it for one corner, then flip it over for
the other side.
I 'framed' the perimeter and cross 'joists' with 1" square aluminum
tubing that was scrounged (used) from a commerciall signmaker's
awning. You can see some of it in the shot with the back section
lifted.
The tubing is held in with a few sheet metal screws and "Lepage PL
Premium" construction adhesive.
I did it in 2 pieces so I could have easy access to some rear storage.
The sections are hinged with a stainless piano hinge from 'Lee Valley
Tools'.
The covering is regular tonneau material, that I glued down with
"Lepage Heavy Duty, High Temperature" spray contact cement (Home
Depot).
The latches I used are from an outfit called "Southco" (Google it)...a
local stock car builder had a couple of extras for $20 each...they
work nicely, but you may want a different look.
Went to 'Princess Auto' for wide, self-adhesive foam gasket for truck
campers, and applied it to the cover, NOT the truck box.
The whole job is fussy and time-consuming, but I get nice comments on
it. You may or may not wish to hinge the aft section (About 30" for
mine).
All told, I think I have about $250 in material tied up. I'm guessing
the whole assembly weighs about 50 pounds...
Front is held down with a couple of good quality bungee cords, you may
want something more sophisticated?
Big tip: The Econoline box is tapered...cut and measure plywood carefully!
Let me know if you need specifics on materials or techniques....I've
never done this before, but I managed to not screw it up too badly !
With the aluminum cross joists, it's pretty strong. I think if a cute
19 year old blonde beauty wanted to climb up on it, I think I'd let
her!
Oscar