Home built canopies

[Falz87]

Im planning on making my own canopy for my Hilux,, just not sure what to use though,, Alloy or steel... Has anyone on here built their own before? obviously i want to keep it as light as possible. so canvas sides will be the go, and checkerplate top.. itll have to be strong enough so i can use it for work,, put extension ladder etc and conduit rack on top therefore a couple of low mounted ladder racks will be necessary. Ive never arc welded alloy before.

anyways, any advice on design or materials would be much appreciated

cheers.

[Orrsum]

I used 25mm box steel for a frame then had a sheet of 2.5mm ally checkerplate folded to fit the shape. also had the frame gal dipped prior to sheeting it. it was a cruiser tray 6' x 8'.8" so i had to hunt around for a larger than normal sheet. i think it was 1550mm X 3000mm.
then attached it with Sikaflex and blind rivets. if you weld a pair of racks onto the top of your frame then you may be able to get away with a couple of smaller sheets. i used the big one cos i wanted no joins.

4 bolts and it came off, still needed it as a ute occaisonally.



Attachment 43141 Attachment 43142 Attachment 43143

[the lobster]

Yeah I reckon you'd have to make the frame, at least, out of steel box section or tubing. If you ever need to carry anything remotely heavy on top it won't be a drama that way.

matt

[shano]

ally is nice but steel is the go for strength. i got a all steel one at work we are going to sell! has ladder racks and also steel locking doors on both sides and the rear! very very strong!

[Falz87]

I used 25mm box steel for a frame then had a sheet of 2.5mm ally checkerplate folded to fit the shape. also had the frame gal dipped prior to sheeting it. it was a cruiser tray 6' x 8'.8" so i had to hunt around for a larger than normal sheet. i think it was 1550mm X 3000mm.
then attached it with Sikaflex and blind rivets. if you weld a pair of racks onto the top of your frame then you may be able to get away with a couple of smaller sheets. i used the big one cos i wanted no joins.

4 bolts and it came off, still needed it as a ute occaisonally.



Attachment 43141 Attachment 43142 Attachment 43143

Was it very expensive to get it dipped and canvases made up?

I'll probably do the same and make it detachable.

whats the best way to go about bracing?

[Leigh77]

When you make the frame, this method will ensure the canvas/PVC (whichever you decide) will fit properly, and look great.

Have your posts coming up from the tray, but when they are just higher then your gates, weld a plate on top. The plate should come out level with the outside of your gates. Then the rest of the canopy is built on those plates (level with gates).

This will make the canvas section sit a lot better, therefor look a lot better.

I have attached a pic so you can see what I mean...The red is the canopy frame, the green is the plate that allows the top section of the frame to be brought out level with the outside of the gates. Obviously since they are on a corner, the plate would have to be cut so it puts the top section of the canopy level with both sides...(side and rear) (side and front).

Hope this helps...If you have any questions shoot me a PM. The prices on the canvas work differs greatly, depending on windows,zips and overall size.

Leigh.

[Orrsum]

Was it very expensive to get it dipped and canvases made up?

I'll probably do the same and make it detachable.

whats the best way to go about bracing?

the Gal dipping cost me a carton of VB, cos i had already had the whole tray dipped, and i bought a sheet of 2.5mm plate steel for the floor(one piece) and had it all dipped and assembled. the total cost was $1100 pretty good deal. with the frame i had the top and then another row below for the strength. see attached and you can see if you look closely. the canvas section was $700 from Noosa canvas and vinyl i used the rip stop canvas, its furry on one side.

Attachment 43192

[Falz87]

awesome. cheers guys, when i get keen, ill post some pics step by step through the build.

[Lucky_Phill]

Made mine from 40mm steel box. Colourbond roof. Sail channel to hold vinyl sides. Has racks on top. I have 3 sets of fluros in the canopy, my second battery hides there as well.

Haven't got too many pics. but....

and yes, I did what Leigh suggested... stepped the uprights out to line up with the tray.

Phill.