Well I got tired of looking for a reasonable product out there that doesnt require me to take out a personal loan or wait for a potential tax return. I got up early today and decided to just go ahead and make a wood one.
I didnt do a detailed how to or anything as every jeep is minutely different and owner preferences vary as well.
1). 4x8 1/2" highest quality sanded plywood that Lowes had
2) wood nails
3) gorilla glue
4) 90 degree brackets
5) circular saw. (didnt have any tools so I gave in and got one. )
Out the door everything cost me about 100.00. I'm planning on returning the saw since I used my jigsaw and it worked rather well so that will make the cost 55.00.
Dimensions for the top and bottom pieces were 35.75x35 (2 pieces)
sides were 10.75x 35 (3) this includes the center section
the front was 10.75x 35.75 if I recall
I was in serious slow/lazy mode today & took my time. It took all day just to get where I got. Cloudly weather has me lagg'n.
The top piece had to be notched where the tailgate lock goes & the left vertical piece had to as well.
A good tip for drilling the holes for the stock seat bolts: use a sharpie & mark the bolts up & then pressed the wood against it, gave it a wack, pull it off & there'll be an impression to drill. Easy breezy. The two torx bolts on each fenderwell & the 4 up front on the floor for the seat are plenty to keep this thing from coming out. I will probably add another section of 1/2" on top so the ply will run the full length side to side fwd of the rear rollbar tie in. As it is it looks to boxy. It'll look more tonneau-ish when I'm done.
Anyways, here's a few pics of the 1/2 finished job. It doesnt show the center section in the pics so no need to comment on support.
I'll also be using rubber/oil resistant on the bottom of it & carpeting the rest inside and out. I should of done this mod yrs ago.