Pattern
Jason tonneau covers or "lids" begin with a conceptual drawing. We use a mound of foam to create a working pattern. A five-axis CNC machine then halves the foam to give us a two-piece pattern.

Test Fitting
After completing and joining the right and left pieces, we test fit the pattern on the truck.

We also use the foam pattern to create a forming plug. Craftsmen fine-tune the master plug, which is used to form the mold that we use to produce the lid.

Parts Production
Molds are used time and time again to form the production parts. To produce parts, we first coat the mold with primer gel. We then laminate it with a sophisticated structure of chopped random-strand fiberglass, reinforced with a resin-soaked honeycomb fiber substrate that forms a hard, resilient solid composite unit that can handle the flexing and tension inherent in a moving vehicle.

We use hand-laid woven fiberglass roving and metal plates to further strengthen stress areas and hardware attachment points.

Final Touches
After the hardware components are installed and the edges trimmed, each lid is hand sanded and prepared for painting. The resulting one-piece molded fiberglass construction sports a multi-layer finished surface of DuPont base coat / clear coat automotive paint.

Inspectors perform quality checks, and then each unit receives a complete hand-wash before leaving the factory.

May we build one for you?