HMMWV Cargo Covers Build Thread

[Bulldogger]

I am starting this thread to share my progress on designing and sewing new cargo covers for HMMWV 4-seat soft top versions, like my own M998. I also welcome feedback on design requirements and desires from other HMMWV owners here.

This is a new product in addition to my HMMWV soft slant back kits (see separate thread). I decided to expand into another form of bed cover after sensing some interest in the owner base of 4-seat rigs. https://www.steelsoldiers.com/threads/hmmwv-4-man-soft-slant-back-feedback-and-discussion.176620/

Sunday I completed a prototype out of desert tan 686 MIL-PRF-20696 18oz vinyl. It is a slightly lighter weight vinyl than the typical MIL-PRF-32002 22oz but plenty strong -- and I have 100 yards of it. I made it the old fashioned way by just draping a huge piece of material over cargo bows and marking, cutting and stitching until it looked like a cargo cover. I spent more time cogitating on how and why to do a step than the actual sewing and fitting.

I'll detail the construction in follow-on posts.

I welcome ideas and suggestions for features and desired functions of these new covers.

Bulldogger

P.S. Sharp eyes will note my avatar has changed! I have contracted a web services company to build a new website for me and it included logo design. I kept the logo simple on purpose, but hope y'all like it as much as I do. I have a laser engraver/cutter machine and am now thinking about making merch. That's probably a ways off, but I love the idea of having my own branded pint glasses and all that (who wants a t-shirt! ?). My website (link in my signature) will launch this week. I have some kinks to work out with the online store therein, but will press to have it finished as soon as able.

 

[Bulldogger]

First I had to set up cargo bows. I got a set from a customer who changed his rig over to one of my soft slant backs.
Military bows seem kinda, scant, in terms of how well they support the cover.
I decided the change that by making crossbars to span between the bows. These bars are 3/4” steel tubing secured with the same kind of clamps I use on my new soft slant back frame design. I plan to offer these crossbars as upgrade to anyone who wants them.

That should support cover better.
BDGR

 

[Bulldogger]

Now to begin patterning the new cover.


I marked the front leading edge and rear opening for where to cut, seam, edge and stitch them.
Each step took an hour bc I wanted to be confident I was going in the right direction. I took written notes so I can repeat the steps once the prototype is sold.
BDGR

 

[Bulldogger]

Now the seams are taking form and I’m planning the rear flap/panel and window.

 

[Bulldogger]

With each major seam I put the cover back on the frame to check all fittings. Then it was time to stitch on the back panel and zippers, locate the grommets and add tie down straps. I’m using ITW NEXUS D rings just like I use I soft slant backs. Ancra buckles can be had, but at $25 each, the added cost is prohibitive, considering this cover uses 13 of them!




This last photo shows what the crossbars look like from inside.
So my first ever cargo cover is complete. There are several steps I will do a little differently on the next one (already started) but this one is serviceable. Look for it in the classifieds if tan is your thing.
More to come!
Bulldogger

 

[Bulldogger]

Time to start a black sailcloth cover. I have a customer for this one already. He has a soft slant back but wants more flexibility for cargo capacity so he’s asked me to make this for him too.
First step is to put 11 feet of material over the bows and begin marking seams and Velcro locations.



The next steps are marked with tailor's chalk and I’ll do some more sewing tonight.
These go together (well, sew together) faster than soft slant backs due to having fewer seams and I don’t have to make a frame. That will help keep costs manageable I hope. I cannot compete with the cost of milsurp covers, as the prices do not reflect construction costs (the Government paid that). However, for custom fabric like sailcloth or other materials the cost will reflect time and materials.

BDGR

 

[Bulldogger]

Progress last night. The front leading edge was trimmed to match the curve of the C pillar and the Velcro strip seen in. The rear hatchway was seamed and defined. Positioning grommets were marked. Also got half the edging done before running out of prepared vinyl edging strips. I folded more so it will be ready for today’s sewing.
Window vinyl is on the way. Customer wants tinted vinyl, which is very hard to find in heavy gauge. I borrowed some from another HMMWV specialist. Will have to order my own once I can afford to make a bulk purchase.