The Simple Upgrade I Used to Protect My Truck Bed From the Elements

Install the bulkhead seal

The bulkhead seal is the foam strip that sits between the bulkhead and the header bar. This prevents water from entering and can help level the header bar to sit inline with the side rails.

• At the front of the truck bed, clean the top of the bulkhead with soap and water to rid of any dirt. You can also just wipe it clean with rubbing alcohol.
• Take the bulkhead seal and attach it to the top of the bulkhead. Then, work your way to the other end, sealing as you go. Trim any excess seal.
• Press down firmly on the seal along its entire length to ensure a watertight bond. Remove the protective film from the top of the foam seal before proceeding.

Install the side rails

The side rails are usually labeled D (driver) and P (passenger) near the front corner cap.

• Place the side rails according to the label on the corner cap, on top of the bed rail. Position the corner cap at the front of the truck.
• Turn over the side rail. Locate the foam pad with four detachable corner weather seals. Peel and press one of the larger corner seals into the bottom corner of the front corner cap. Repeat on the other front corner cap.
• Flip them back over and place them on the bed rails. Ensure that the weather seal is flush and flat against the bed rail.
• Align the inside edge of the side rails with the inside edge of the bed rail. The end of the side rail should align with the back of the bed rail, where the inside of the tailgate sits when closed.
• Place three clamps on each side. One at the front, middle and back of the side rails.
• Tighten the side rail to the bed rail with the clamps by hand, as you will need to adjust the side rails later to fit properly. Connect the clamp’s teeth to the small channel grooves on the side rail, and secure the bottom of the clamp under the bed rail.

Install the header bar

The header bar contains the vinyl cover assembly.

• Set the header bar on top of the bulkhead seal and center it. Ensure that the straps for the cover hang down and are not caught between the bulkhead seal and header bar. Align the ends evenly on both sides.
• Insert one of the connecting corner caps of the side rail into the open cavity of the header bar. You may need to loosen the clamps slightly to connect them. There is no click or locking mechanism when you connect the corner cap to the header bar, so check that the header bar is flush and square at the connection. Repeat on the other side rail.
• Ensure the header bar is centered on the bulkhead with the side rails connected before moving on.

  

Unroll and align

As mentioned in previous steps, you will need to adjust the side rail clamps to ensure a secure and aligned fit.

• With the cover and header bar centered on the bulkhead, unroll the vinyl cover slowly back towards the tailgate.
• As you unroll, align the side rails so the cover’s cross bars sit between them. Move the side rail clamps, if needed, so the support bars do not rest on them.
• When you reach the tailgate, drop the end of the attached tail rail into place so it clicks into the side rail at the tailgate. There should be approximately a 1/8-in. gap between the tail rail and the side rail to allow it to properly latch.

Secure the clamps

Tighten all six clamps with a socket wrench.

• Unlatch and roll up the cover. Use your socket wrench to tighten the end clamps near the tailgate on both sides.
• Double-check that the header bar is still centered and fully connected at the corners. Then tighten the front clamps near the bulkhead.
• Move down to the middle clamps and tighten.
• Roll out the tonneau cover back to the tailgate and latch it in place to test the fit.

Final adjustments

• Unlatch the tail rail by pulling the cables downward at both ends. Roll up to expose the bottom corners of the tail rail.
• Place the last two small foam corner seals at the corners of the tail rail. Align the corner seal to the corners of the tail rail. Latch the cover and close the tailgate, ensuring it doesn’t hit the tailgate.
• To eliminate wrinkles, starting from the front, peel up the velcro edge on the side rail. Pull it taut and back towards the tailgate. Velcro it back down and work your way down to the tailgate.
• Switch over to the other side and repeat.

FAQ

Does a tonneau cover improve gas mileage?

Yes, but this also depends on the type of truck bed tonneau cover you have installed. Tonneau covers reduce drag in your truck, making it easier for you to reach your designated speed. Soft folding and soft roll-up tonneau covers are lightweight and don’t add much weight to the truck. As for heavier-duty tonneau covers, they will not improve your mpg as they add significantly more weight to your truck.

How is “tonneau” pronounced?

“Tonneau” is pronounced tuh-NOH

How should I clean a tonneau cover?

Wash your tonneau cover at a self-service car wash station or hand-wash it at home. Avoid automated car wash stations with brushes, as they can damage your tonneau cover and may shift it over time. If you must take it to a car wash, use a touch-free car wash station, which uses pressurized water and detergent rather than brushes.

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