Text
and Photos by Sam Haymart (shaymart)
Posted February 17, '03
 I
recently purchased a Saleen one piece toneau cover. Because the
cover must either be on the car or stored, a safe spot to keep it
and protect it is a must. There are many solutions for storing the
hard covers available for your Mustang. Some companies offer padded
zip up slipcovers and others have hoist mechanisms. These are all
great solutions but can be costly.
As this family has three kids which see everything in the garage
as an opportunity to build a fort or swing from I needed a storage
device that was out of the way. This is also a result of my being
a nut for having everything tidy and organized. Being budget minded,
this project was done for maximum savings with a total cost of about
$75
Items Needed:
- 1 4x5 foot OSB / plywood
- 1 3x5 foot OSB / plywood
- 2 5 foot long 2x4 lumber
- 1 4-5 foot “piano hinge”
- 1 1” thick foam padding (approx 25 square feet)
- 1 2” thick foam padding (approx 10 square feet)
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- 2 eyebolts (threaded with nuts and washers)
- 2 eye bolts (screw thread)
- 2 large washers
- 1 1/8” rope/cord (approx 15 feet)
- 1 3M Super trim spray adhesive
- 2” wood/deck screws (lots)
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Procedure:
Note: Some full-sized
images have additional information, arrows, etc.
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Step
1
Attach 2X4 to bottom edge of 4x5 panel with deck screws at
approx 6” on center.
Affix
the panel to your wall. Depending on the surface, you many
need to use a different method. I had 5/8” gyp. board
over 5/8” plywood sheeting so my 2” deck screws
worked well.
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Step
2
Install “piano hinge” to the remaining 2x4 and
then attach to the one hanging on the wall.
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Step
3
With the help of a pal, hold the 3x5 panel in place and attach
to the hinged 2x4 in the same fashion as the first one.
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Step
4
Now that you have a hinged assembly, install the threaded
eye bolts to the outside edges of the horizontal panel, and
the screw thread eyebolts to the wall panel. Be sure to align
them so they are vertically congruent to one another
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Step
5
Using the large washers as a stop, tie the to equal lengths
of rope and feel them through the top eyehooks, tying the
opposite end to the eyehooks of the horizontal panel. You
should prop the lower panel up level when tying off your lower
hooks.
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Step
6
Once the structural portion is complete you need to bond the
foam padding to the panels with spray adhesive. Be sure to
have your cars out of the garage when using this stuff, it
is evil. The 2” thick portion should be used at the
bottom hinge point area as the toneau cover is the thinnest
at this point and need the most support.
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| When attaching the thick pad, bond it ONLY TO
THE BOTTOM PANEL. This allows the open and closing operation
to occur properly without pulling or stretching the material
(see photo). Once this piece is bonded, shut the panel to the
upright position and measure the proper distance for the 1”
padding. Complete the bonding of the 1” thick padding. |
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Step
7
Mount screws at the bottom of the wall side 2x4 to hook your
ropes to when securing panel in upright position.
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Finishing
Up
Paint and finish as desired.
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Its Done!
This project is a one-day item and can be done in many ways. I
am a quick fix “get it done” kind of guy so I didn't
spend a lot of time being a perfectionist here. The end result is
that is works, fits the cover perfectly, and will keep it safe from
the kids.
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