Step 1: Materials
Coats & Clark Extra Strong & Upholstery Thread $3.00
1 Yard - 18oz vinyl coated polyester (I had leftovers from the tonneau cover I made, some black and some white). I purchased it from ChicagoCanvas.com. Great people there.... very helpful. $7.50
54" 1/2 aluminium electrical pipe $3.00
HH66 glue (also from ChicagoCanvas.com) $11.00
Step 2: Measurements
Bottom Piece - Black
The wheel well starts 16" from the edge of the bed. I added two 5/8" seams plus 2" so it would rest in the door jam (pictures later). So the bottom piece was cut 19.25" x 54.25".
Top Piece - White
I measured the height from the bottom of the bed to the tonneau cover rail, 18". I added 5/8" seam allowance plus roughly 6" to make a pocket for the tube to go through. So I cut the top piece 25" x 54.25.
Step 3: Sewing the Top and Bottom Seam
Sailrite has an awesome video if you're interested. https://youtu.be/uFSn-EIgQoc
I just used scrap vinyl for the backing binding strip.
Step 4: Anchor Ties
Cut a 6" x 16" vinyl strip
Coat one side with HH66 cement
Wait for it to dry
Fold in half longways to make a 6" x 8" piece
Zig zag stitch starting 1" down from the folded edge, making a 1/2 wide, 3" long opening
Cut out the opening
Zig zag the edges
Sew fuzzy side of 2" Velcro to both sides of the openings
Cut two 4" long pieces of the scratchy Velcro to use for the installation.
Step 5: Side Seams
Add the tie down tabs on each side, up 4" from the tailgate edge. The bottom of the notch should be 1" from the side.
Step 6: Top Seam
On the back side of the top...
Refer to my crappy drawing.
Brush a 2" line of HH66 along the edge of the top.
Leave 4 " clearance, then brush a 2" line of HH66.
Once it's dry, fold the end over and match up the glue to make the tunnel for the pipe.
Step 7: Pipe
Wrap both ends with the fuzzy side of 2" Velcro.
Slide the pipe through the tunnel you just made on the top of the white section.
Step 8: Installation
Next, put the bottom edge in the tailgate jam.
Slip the tabs over the tie downs and insert the Velcro locks on both sides.
Step 9: Thoughts
The French seam was fun to try, and crazy strong.
HH66 is AMAZING. It's easy to use and stronger than the material.
When I don't need it, I can fold it up and stick under a seat. I can also roll it up with the tonneau cover!