- 1). Measure the length and width of your truck bed on all four sides. Cut two pieces of 2-by-4 with the saw which equal the length of the bed. Cut one piece of 2-by-4 which equals the width of the bed at the cab.
- 2). Cut one piece of 3/4-inch plywood to dimensions which equal the dimensions of the truck bed. Use the measurements you previously took and draw a pattern on the 4-by-8 foot plywood. Cut along your lines.
- 3). Measure 3/4 inch down from the top of the side edges of the truck bed and make a line with the pencil. This is where the 2-by-4 length pieces will be placed. Measure 1 foot along the line you just made toward the center from both the cab and the gate and make two marks 1 inch apart. These marks are the locations of the holes you will drill and should be approximately 1 inch below the line for the 2-by-4 side piece marks you drew. You should have eight marks (two per end on both ends of each side of the bed).
- 4). Drill holes through the side of the bed using a 1/4-inch metal drill bit at the marks you made. Measure 1 foot along the 4-inch side of each of the side piece 2-by-4s and make marks which correspond to the holes you drilled in the truck bed. Drill holes through the 2-by-4 side pieces.
- 5). Attach the side pieces to the side of the truck bed by placing the 2-by-4 over the area with the holes. Place a fender washer over the holes between the 2-by-4 and the truck bed. Place another washer over the hole on the other side of the board. Place a locking washer over the fender washer and place the 3-inch bolt in the 2-by-4 to attach it to the truck. Repeat this for all eight holes, completely fastening the side rails to the truck bed. The rails should sit 3/4 of an inch below the top of the bed sides.
- 6). Cut a 2-by-1 inch notch in both ends of the piece of 2-by-4 the size of the bed width. When you are finished, the pieces should look like a "T," be able to fit on top of the side rails and be even with the top of the bed. This is the brace for the cover piece. Screw this piece to the side rails using a screw driven through each side of the brace piece and into the side rails.
- 7). Space the top part of the three T-hinges and screw them into the cover brace. Attach the piece of plywood to the hinges so it creates a bed lid which swings up towards the cab. When closed, the lid should completely cover the bed, and the top of it should be even with the top of the bed.
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