My Own Canopy - Hilux Revo





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  1. #1
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    Default My Own Canopy - Hilux Revo

    Good day fellow 4x4 community members.

    I have been on a mission to design and fabricate my own canopy for my 2018 Hilux D/C. The canopies on the market have a lot to offer but don''t always tick the right boxes... for me anyways.

    So, I have been thinking about making my own. Thinking eventualy ended up in designing and getting ideas from all the various options available out there. A friend of mine did his own for his Hilux Vigo and it has convinced me to go the same route. Fortunately my line of work puts me in contact with sheet metal fabricators and I have enlisted their help.

    The frame is made from Mild Steel. Laser cut and cnc bent. Doors will be made from Mild steel frame and clad in Aluminium sheet. The roof will also be Aluminium sheet. The finish will be done with Raptor Coat as I think it will give it a unique finish. Best of all the product can be tinted to any desired colour. Will be a two tone finish to match the existing colours on my Hilux.

    Firstly it started off with some CAD... (Cardboard Aided Design)...


    Followed by some proper CAD by means of Autodesk Inventor...


    The first test fit happened yesterday...
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    Last edited by Birra; 2019/10/17 at 01:22 PM.
    2018 Toyota Hilux 2.4GD-6 D/C 4x4 A/T

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  3. #2
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    Default Re: My Own Canopy - Hilux Revo

    Subscribed. Looks like a winner already

    Keep us posted
    Last edited by Pietsweis; 2019/10/17 at 02:04 PM.
    If Force is not the solution, not enough of it was applied....

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  5. #3
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    Default Re: My Own Canopy - Hilux Revo

    Looks very interesting and like you have a good idea/design

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  7. #4
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    Default Re: My Own Canopy - Hilux Revo

    Lyk netjies man onthou om foto op te sit as jy klaar is

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  9. #5
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    Default Re: My Own Canopy - Hilux Revo

    Have you included a flap to allow air in to pressurize the canopy and keep dust out? this is a problem with a lot of canopies.

  10. #6
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    Default Re: My Own Canopy - Hilux Revo

    Quote Originally Posted by RonS View Post
    Have you included a flap to allow air in to pressurize the canopy and keep dust out? this is a problem with a lot of canopies.
    Hi RonS,

    I have taken that into account. The Front window will be a slider type. Will crack the window open when required to serve as pressurization for the Canopy.
    2018 Toyota Hilux 2.4GD-6 D/C 4x4 A/T

  11. #7
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    Default Re: My Own Canopy - Hilux Revo

    Good evening all,

    Some update time... So I got the frame back today and overall I am very pleased with the outcome thus far.

    Now for the door frames to be made. Then the alu sheeting and paint. Some areas that needs some love with some welding and grinding to give it the 100% finished look I am after....
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    2018 Toyota Hilux 2.4GD-6 D/C 4x4 A/T

  12. #8
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    Default Re: My Own Canopy - Hilux Revo

    Do you mind sharing what Tig welder you are using?

  13. #9
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    Default Re: My Own Canopy - Hilux Revo

    As this isn't really about Toyota, it should be in a more general area that all can see.

    It looks brilliant if you ask me. It shows what can be done if you have resources.
    Mercedes W123 300D, runs on Mother Natures Goodness.
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  14. #10
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    Default Re: My Own Canopy - Hilux Revo

    Quote Originally Posted by Birra View Post
    Good evening all,

    Some update time... So I got the frame back today and overall I am very pleased with the outcome thus far.

    Now for the door frames to be made. Then the alu sheeting and paint. Some areas that needs some love with some welding and grinding to give it the 100% finished look I am after....
    Looks good

  15. #11
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    Default Re: My Own Canopy - Hilux Revo

    Looks very Good!

  16. #12
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    Default Re: My Own Canopy - Hilux Revo

    Thanks Guys.

    Its just taking too long for my liking, but getting there.

    To answer Tiaan Pot's question: I haven't used a TIG welder on this. The sheet metal fabricator welded the skeleton for me. They used MIG welding. I will be using my ARC/TIG welder to do the welding for the door frames and the brackets i still need to design and have made.
    2018 Toyota Hilux 2.4GD-6 D/C 4x4 A/T

  17. #13
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    Default Re: My Own Canopy - Hilux Revo

    How are you planning on mounting the canopy to the bak? I only ask as I see the vast majority of canopies on newer bakkies with the smooth sided baks (rather than with the rolled edge) are mounted to the floor of the bak with a bracket system, rather than on the side rails as it seems these are not really long term load bearing.

  18. #14
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    Default Re: My Own Canopy - Hilux Revo

    Quote Originally Posted by niclemaitre View Post
    How are you planning on mounting the canopy to the bak? I only ask as I see the vast majority of canopies on newer bakkies with the smooth sided baks (rather than with the rolled edge) are mounted to the floor of the bak with a bracket system, rather than on the side rails as it seems these are not really long term load bearing.
    I believe the better way of attaching the canopy to the bin is by means of brackets. I am planning to make brackets that attach to the factory load bin tie-down points with tabs/brackets on the canopy. All the locating holes will be slotted to allow for adjustments where needed. This should then allow for the movement of the canopy on the load bin to happen within a controlled manner thus avoiding possible damage to the load bin itself.
    2018 Toyota Hilux 2.4GD-6 D/C 4x4 A/T

  19. #15
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    Default Re: My Own Canopy - Hilux Revo

    If you have to compare costs, with those readily available on the market ... are you saving or drowning?

  20. #16
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    Default Re: My Own Canopy - Hilux Revo

    Quote Originally Posted by Morne - Skip View Post
    If you have to compare costs, with those readily available on the market ... are you saving or drowning?
    So far I am saving... A LOT. I will do a cost breakdown once it is all completed. But so far I can ball park it under R8000 completed
    2018 Toyota Hilux 2.4GD-6 D/C 4x4 A/T

  21. #17
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    Default Re: My Own Canopy - Hilux Revo

    Hi All, thought I would share the final product...

    The rear door needs to be redone, as didn't have enough time to finish it with a window before we left for Holiday last year. But that should take me longer than a Saturday... I am very chuffed with the outcome and it works real good.

    Cheers.
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    2018 Toyota Hilux 2.4GD-6 D/C 4x4 A/T

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  23. #18
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    Default Re: My Own Canopy - Hilux Revo

    That is damn smart. Tell us about the material and finish on the doors.

  24. #19
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    Default Re: My Own Canopy - Hilux Revo

    Very nice. Like the look of the doors...

  25. #20
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    Default Re: My Own Canopy - Hilux Revo

    Quote Originally Posted by plunger View Post
    That is damn smart. Tell us about the material and finish on the doors.
    I used 1.6mm Mild Steel for the frame, 25x25x2mm Angle Iron for the door frames, 2mm mild steel sheet for the front panel and rear door. Side doors and roof is covered with 2mm (6WL Rigidised Patern) Aluminium Sheet. i bought the hinges from Mac Naughtans in Alrode, the gas struts and latches from 4x4 Direct in Boksburg and all rubber at Pro Auto Rubber in Boksburg.

    The ball park figure is at about the R10k mark at the moment, just need to get the cabslider and rear window done. I am planning a full cost breakdown after the build is done.

    I am planning to design and build a roof rack soon with a hinge/bracket to mount a table on the inside and also a kitchen unit in the near future.
    Last edited by Birra; 2020/01/22 at 08:12 PM.
    2018 Toyota Hilux 2.4GD-6 D/C 4x4 A/T

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