(A.R.E.) Tonneau Cover T-Handle Converter

The locking mechnisum on my A.R.E. tonneau cover installed on my Chevy Silverado has been slowly falling apart for the last few years. The plastic has been breaking apart and the lock has given out to where i could barely get the back to lift up. I looked at replacing it but the offical ones were $300+, all the junk yards one were just as broken, and nothing in the way of an aftermarket replacement. So i decided to replace it with a T-Handle lock and just 3d print all the other pieces.

This is the T-Handle i choose because of the length bar itself to reach back to the junction (https://a.co/d/51ooejq). You only realy need the T-Handle itself and the keys.

A lot of test pieces later i got a design that would fir my tonneau cover's curve and allow the handle to freely move and turn the junction bars. You'll need a 1/8 allen key detach the old bar from junction at the collar. My old one had broken apart and fell out but, you may need to further unscrew things to it get the old lock removed leaving you with just a hole in the Tonneau cover. You will also still need the locking bars and collar that actually turn and "lock" the cover in place.

The T-handle will need to be attched to the Inside Piece first with two 5mm bolts. The holes in the T-Handle are treaded so screw it in from the back to it can pull the printed piece tightly togerther. Some nuts or acorn nuts will cover the protruding threads and ensure it stay in place. Test fit the inside and outside together to ensure you have room to turn the T-Handle. I included an additional spacer if you need of more clearance beyond the one already in the design.

The Outisde piece should sit inside the hole and flush-ish againist the tonneau cover. The T-Handle will pass horizontal though this piece and if then turned veritcally will stay in place while you screw the two pieces together. I installed two 4mm threaded heat inserts in the outside piece to get a good soild connection between the two; I didn't find a need to install any on the inside piece. It is tricky to get it aligned right but it should screw together using two 4mm bolts using the heat inserts or 6mm i you just go raw. Once its tight you can go back and put some silicone around the edge to get a weather proof seal.

Now you just need to attach the square bar to the junction collar in the back and test for a smooth action to find where to lock it down with the set screw. I can finally lock the cover while on vacation again and not struggle to get the lid to lift up without jiggling it.

Extra: So i also broke one of the locking bar guides things that hold the bars up. So i design a replacement for that as well.

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Category: Other