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  1. #1
    Join Date
    Sep 2007
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    Adelaide
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    26

    Default Ideas for ute 1/2 canopy

    Hi Everyone,

    I am thinking about making a half canopy for my single cab ute. I had a look around at buying one already made and while there are some good ones out there I just can't at the moment justify the $1,000 price tag to buy one.

    I was thinking something that I can throw things in to keep them a bit more secure. and to put an esky/fridge in for camping. Something similar to the picture below.



    I would want to make it a little smaller thought, keep the height the same as the cab, and for it to still sit behind the tray sides. Although this could be annoying if things in the back are tied down, as you couldn't then get into it without untying ropes etc.. but I'll work on that idea.

    So back to the design. I have a good welder and am capable of sticking steel together, but can't do alloy at the moment.

    Materials;
    Frame: 25x25x2mm Alloy; or same size steel
    Sheet: 2mm flat alloy

    I would like to keep the weight down, so was going to do alloy frame, get someone to weld the frame together and then I could sheet the outside by pop riveting the sheets to the frame.

    The other option is for me to weld a similar size steel SHS and then do the same as above.

    So what the general consensus of my learned fellows, are the sizes enough for it to be durable?

    I guess one advantage of a steel frame is I could include some reinforcing on the back wall to bolt on fuel can/spare tyre brackets...

    Also, I am having trouble trying to work out the best way of ensuring the doors are weather tight. I guess I could shape up some alloy angle and have someone weld it in. then I could stick some rubber strip on it to keep the weather out?

    When I pop rivet the sheet on, I was thinking about sticking it all on with silastic first to hold it in place and help seal it. Then use 25x25x1.6mm angle and pop rivet through this to neaten up the edges. Over kill?

    Just a bit worried it may all end up looking a bit jerry built

  2. #2
    Yonnee's Avatar
    Yonnee is offline Trailer Bloke & Mild Mannered Moderator
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    May 2007
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    Tooradin, Vic.
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    Default

    If you're going to pay someone to weld all the aluminium together, the labour costs aren't going to be much different from buying a ready-made one. If your welding skills are any good, you could fabricate it yourself from 25mm SHS Duragal.

    Also, doing it yourself allows you to make changes as you build it, or even afterwards, but getting an alloy frame made requires you to know exactly how you want it at the start.
    Too many projects, so little time, even less money!
    Are you a registered member? Why not? click here to register. It's free and only takes 37 seconds! Doing work around the home? Wander over to our sister site, Renovate Forum, for all your renovation queries.

  3. #3
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
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    Hi, I would make the frame out of steel as any one can weld it, if there is a problem. Cladding it in mesh makes it very secure particularly if 50X50 is used, then have a canvas cover made for it, zips on the sides for the door. Nice and tidy and weather proof. Doesn't matter if it looks Jerry built as the canvas will cover it.
    As Yonee said getting someone to fabricate it from ally or sheet will cost as much for a ready made, if not more, the biggest problem is weather proofing, a lot of extra folds in sheet metal is involved, been there and done that.
    Kryn

  4. #4
    Join Date
    Sep 2007
    Location
    Adelaide
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    Default

    Thanks for the feed back Yonnee & Kyrn,

    The steel frame with mesh/canvas is definitely an idea to consider.

    As mentioned it may end up being quite expensive to get someone else to weld up the ally frame.

    I had wanted to keep it light as I will need to be able to maneuver it on/off, on my own.

    I often see boxes for sale locally, that run lengthways along the tray. Maybe I might be better off just grabbing one of these.
    Although they are quite a bit smaller.

    Anyone used one and can provide comment on functionality? Does it tend to weigh down one side too much?

    I guess the benefit of one of these boxes is that you still have the full length of the tray down one side.

    Had a quick look on evilbay and some boxes can be picked up cheap.. made in China I guess but at around $4-600 for a box such as the ones below it sounds ok.





    Anyone have opinions good/bad on these types of boxes?

  5. #5
    Join Date
    Jul 2008
    Location
    Sydney
    Posts
    210

    Default

    If you're looking at $4-600 for an alloy half box save a few more pennies and buy a proper ute back.

    $600 to $1,000 isn't a lot and the difference in what you get is a whole lot more.

  6. #6
    Join Date
    Sep 2010
    Location
    Lebrina
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    Default

    Those boxes will leak like a sieve and will not be easy to seal due to their design. Having said that, you will not get a cheaper box than the chinese built versions. You do get what you pay for though and often seams are not actually welded and the carcase is very light material

  7. #7
    Join Date
    Aug 2009
    Location
    Caversham WA
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    FYI if you don't already know.

    The canopy / tray in the picture in the first post is made by Bosston. My previous work vehicle was a Rodeo crew cab with a Bosston canopy. From what I recall, the canopy cost around $10000 new.

  8. #8
    Join Date
    Jan 2004
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    Mackay North Qld
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    6,446

    Default

    Quote Originally Posted by monkeyrelish View Post
    Materials;
    Frame: 25x25x2mm Alloy; or same size steel
    Sheet: 2mm flat alloy

    I would like to keep the weight down, so was going to do alloy frame, get someone to weld the frame together and then I could sheet the outside by pop riveting the sheets to the frame.

    Just a bit worried it may all end up looking a bit jerry built

    Just a word of warning about electrolysis when you mix ali and steel.Alloy on steel does not mix too well.One will have to be separated from the other.Without the separation electrolysis happens.

    You get rust where rust should not occurr.

    Grahame

  9. #9
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    Sep 2010
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    Lebrina
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    Quote Originally Posted by Grahame Collins View Post
    Just a word of warning about electrolysis when you mix ali and steel.Alloy on steel does not mix too well.One will have to be separated from the other.Without the separation electrolysis happens.

    You get rust where rust should not occurr.

    Grahame
    Too true.
    Sikaflexing goes a long way, but you do need to put real thought into the design. Not too many rivets either. Sikaflex will do the job without rivets.
    With a smart design, a frame is possibly not required anyway.

  10. #10
    Join Date
    May 2011
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    Murray Bridge S Aust.
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    Default

    Hi monkeyrelish, do you have access to a sheet metal folder?
    If you could to get to Murray Bridge, I could help design your canopy, if you want, as I have experience doing several units similar to what you are looking for, no frame work involved just folded sheet metal.
    Send me a PM if you want to go ahead with it.
    Kryn

  11. #11
    Join Date
    Sep 2007
    Location
    Adelaide
    Posts
    26

    Default

    Quote Originally Posted by KBs PensNmore View Post
    Hi monkeyrelish, do you have access to a sheet metal folder?
    If you could to get to Murray Bridge, I could help design your canopy, if you want, as I have experience doing several units similar to what you are looking for, no frame work involved just folded sheet metal.
    Send me a PM if you want to go ahead with it.
    Kryn
    Hi Kryn,

    Thanks very much for the offer. Unfortunately I am in QLD now(haven't updated my profile) and am looking for the ute box for the trip back to SA.

    I think at this stage I am going to save a bit more cash then buy a decent one.

    Thanks everyone for your input.

    Cheers

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