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.

 

[Bulldogger]

Finished and boxed yesterday. Headed to Florida to a soft slant back customer who wants the option for a cargo cover also.
The design will keep evolving I’m sure but this cover should do just fine in the field.
I plan to make these only in sailcloth moving forward.
Bulldogger

 

[M1028A1ShelterCarrier]

Please make this for the M1165 hard top???

 

[juanprado]

With your improved rear bar support system, can the stock curtain also be used?

 

[Bulldogger]

Please make this for the M1165 hard top???

Not sure how I would do that. I rely on the double Velcro strip along the rear of the milspec soft top to attach the front of the cargo cover (per the original design).

I am aware of Velcro-fitted aluminum strips that were used on the H1 and on other outdoor equipment, which might be fitted to allow for the cover to attach, but it is not a small mod nor is it tested. I have tried other adhesives to attach Velcro to CARC and other painted surfaces and they ALWAYS let go eventually. Any adhesive strong enough to bond those kind of materials together is also likely to degrade (dissolve) the actual Velcro, making it a mixed blessing.

So for now I'm only able to serve 4-man soft tops.

Something you could do is buy a second HMMWV, M998, to keep your M1165 company. It does look lonely... Failing that, there is a market for those rear bows you're not using.

Bulldogger

 

[Bulldogger]

With your improved rear bar support system, can the stock curtain also be used?

Absolutely! The cargo cover itself attaches along the outer rear edge of the soft top. There is no impact on the fitment of the 4-man top itself nor the rear curtain. I have the curtain always mounted in my M998, with the center section unzipped and rolled up. (I added an oversized window and zippers either side of it some while ago.) I like the mod'd rear curtain bc it lets me isolate the bed when I'm carrying messy stuff, but otherwise keep the interior open all the way back but still protected thanks to the soft slant back or cargo cover, whatever is mounted.
Specifically as to the cross bars, they fit across the bows themselves, which come close, but do not touch, the rear of the 4-man top and C-pillar. On my bars, as pictured, the middle bar is exactly centered on the bows, which is only possible because the turnbuckles on the bows have been removed (broke off before I got them). Standard bows have three turnbuckles to allow a milspec cargo cover to attach by large flaps. These flaps are just to hold the cover on while mounting it, the real holding power is the Velcro and side tie straps.

Below is what a modified/improved rear curtain looks like. This is a 2-man, but it's pretty much the same for the 4.

But to your original question, any of my bed covers (cargo, soft slant back) will mount with the existing top/curtain without any interference, and the cross bars can be used with standard bows without interference with the soft top or curtain.

Edited to add a picture of the front of the bars I just found.

BDGR