Toyota HiLux tonneau covers and lids guide

If you’re not interested in a canopy or service body but still want to keep your tray dry and lockable, a tonneau cover is the solution.

A good tonneau provides enhanced security and weather protection, and cosmetic benefits. Let's take a closer look at some of the best options on the market for HiLux owners.

• What it is: A lid or cover for the tray of the ute.
• Why you need it: Your HiLux will come from the factory with an open tub, which is great for storing and carrying gear until it rains or you need to park the ute unattended. To protect your gear from the weather and prying eyes you will need to cover it.
• Buying tips: Tailgates aren't dust or waterproof, so a tonneau cover doesn't provide perfect protection - so consider buying a canopy, which will give you a lot more protected loadspace. The man advantage of a tonneau cover is that it opens up and the tub is then accessible, unlike a canopy. Some tonneaus are electrically operated, others are manual; while some lift up and some scroll back.

Here are four products we recommend. They’re intended as a starting point, to give you an idea of what’s available.

JUMP AHEAD

• Toyota OE
• Ironman Slide-Away
• Flat Top E Series
• Maxliner

Toyota hard tonneau

A simple option for those who just want to secure gear in a tray, the factory Toyota option is lightweight and includes a single-handed latch, central locking and internal lighting for optimal convenience and ease of use. An optional Dust and Water Defence kit is available for additional protection in extreme conditions.

Specifications

• Material: Aluminium
• Finish: Colour-coded
• Operation: Gas strut lift

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Ironman 4x4 Slide-Away tonneau

Imagine a garage roller door over the top of your tray. That’s pretty much what this Ironman 4x4 Slide-Away tonneau cover is. Featuring electronic operation, this is another practical solution to secure your gear from both prying eyes and the weather.

Specifications

• Material: Aluminium
• Finish: Powder-coated
• Operation: Electronic

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Flat Top electric tonneau

A fully automated, press-of-a-button lifting tonneau cover that not only looks good but genuinely is one of the easiest tonneaus to operate.

Featuring a honeycomb structure that is rated up to 110kg static load, and quick-release pins for ease of removal, the tonneau cover is strong and user-friendly. A ‘monsoon’ channel along the front improves the weather sealing even further, and the electronic operation provides improved security.

Specifications

• Material: Aluminium honeycomb
• Finish: Colour-coded
• Operation: Electronic

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Maxliner Hard Cover 180

Innovative design that allows this entire hard lid to lift up means that accessing gear at the front of the tray is easier than ever. With single-hand operation, a simple rise at the rear will lift it at 45°, and a push on the front will lift the entire lid and provide access to the entire tray.

Specifications

• Material: Poly
• Finish: Various colours (texture)
• Operation: Gas strut

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Buyers’ guide for tub top canopies

As with any piece of aftermarket gear added to a 4x4 build, it’s important to first establish what your intended purpose is: Are you a tradie looking to keep your tools safe? Perhaps you’re planning your next Red Centre run?

“We suggest to identify your intended usage and preferences,” Hannah van der Sluys, Ironman 4x4’s Alu-Cab brand manager, advised. “Is it going to be for trade tools, general storage, weather resistance, security, styling etc. Each canopy on the market offers a unique set of benefits, choose the right one that fits your needs.”

Once that’s established and you’ve started the long, tedious process of browsing aftermarket catalogues, there are a handful of essential elements to keep in mind, as Gräbe de Villiers from South African company RLD Design explained.

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“Compare apples with apples,” he said. “Material; coating finish (powder coated or not); do you have to assemble the product yourself before you can fit it? Would you be able to replace components easily? Fitment (does the product bolt on to the OEM mounting hooks in the load-bin? Lead time to obtain the product; and, most importantly, aesthetics ... does the canopy complement the ute and add value?

“Don’t go for the cheapest option and also don’t buy something simply because of its name,” he added. “Make sure about the value for money and also the expandable accessories that could be fitted after fitment or as your need to expand arises.”

Thomas Harding added that other important factors to consider include roof-load capacity; side-door access to cargo; air-pressure vents (to reduce tailgate dust ingress); the finish of the welding and fabrication; the range of accessories (roof racks, drawers, etc.); and, for pooch lovers, whether it’s dog-friendly.

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“While researching, we strongly encourage creating a checklist to help determine what constitutes your ideal canopy,” Harding said. Sage advice.

As with any off-road purchase, ensure the supplier has a quality reputation and can back its product with aftermarket support and a substantial warranty. On this point, it’s important to ensure that the tub topper mounts on the prescribed loading points of your vehicle, as it could create a lot of unnecessary headaches with OEM warranties and the like down the track.

When asked what gets customers riled up the most, Troy Bignell told us that small access points are one of the most common frustrations. “Before getting something installed, try to find someone with a similar setup and see how much of the back you can access,” Troy advised.

Materials

Canopies come in a variety of shapes and sizes and are constructed using different materials, with your budget typically dictating what path you’ll head down when the time comes to swipe the credit card. Typically, you’ll have to choose between stainless steel, fibreglass, aluminium/metal, or a form of plastic construction.

The new breed of canopies are made from stainless steel or aluminium and offer greater roof load-carrying capabilities, sturdier construction and extra durability.

Troy Bignell from Camp King Industries tells us that there are a number of benefits to running an aluminium tub topper over a fibreglass option.

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“The biggest benefit is its ability to bear loads much greater than its counterparts,” Troy told us. “Most fibreglass canopies can only carry a load of 50 to 70kg without some sort of additional internal frame. Most aluminium canopies are rated for 300kg-plus and weigh about the same.

“A secondary benefit of this is that due to the rigidity of aluminium, you can have much larger door openings, making it significantly easier to access your equipment in the back.”

Hannah from Ironman 4x4 added: “Aluminium construction provides a rigid chassis for a more sturdy and robust construction. Aluminium offers great resistance to weather and the elements.”

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Keep in mind, however, that metal fatigue is more prominent in aluminium than stainless steel, so aluminium may have a tendency to crack more easily over time.

Stainless steel is an extremely strong and versatile material and, contrary to popular belief, isn’t as heavy as you’d think, as Gräbe explained: “Due to the strength of the stainless steel the canopy can be manufactured from much thinner – and therefore lighter – sheets, without sacrificing strength.”

As an example, RLD Design’s stainless-steel canopies have a starting weight of 75kg, which is almost negligible when compared to a vehicle’s carrying capacity of at least 750kg.

Weighty issues

By installing a canopy, like a tub topper, and then loading it with tools and/or gear for your next camping trip, the kilograms will begin to rise. This is why it’s critical to always monitor your vehicle’s weight and not overload it.

“Like any accessory on your vehicle, it is going to reduce the load carrying capacity as it increases the overall weight of the vehicle,” Troy told us. “This is why it is incredibly important to look for a lightweight yet still incredibly strong option.

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“It is incredibly important not to exceed the manufacturer’s specifications. Not only because it can void your insurance but also because it can make your vehicle unsafe, increase wear and tear, and make it more prone to failure.”

Canopies provide a great way for tradies to house their tools overnight, while also keeping them sorted and secure during transit. Tools can be heavy, though, and their weight can quickly accumulate, adding to the total weights of the vehicle.

“For this reason, the weight of the canopy itself should be kept as low as possible,” Hannah van der Sluys explained.

How we review products

4X4 Australia has been reviewing four-wheel drive vehicles and aftermarket products for more than 40 years.

When looking for the best accessories for your make and model of 4WD, there are some things essential to making sure you have the best off-roading experience.

When we compare products, here are some of the things we consider:

• Warranty
• Build quality
• Value for money
• Time and ease to set-up/install
• Weight
• Fit and finish
• How well it gets the job done
• What materials they’re made from
• Corrosion/UV resistance
• Coatings
• Compatibility with other accessories
• Compliance with ADRs and vehicle safety systems
• Country of manufacture
• Load ratings, to determine what's the best product across each price point.

We also consider user reviews and our own experience with these products to make sure our recommendations are for the best on the market.

Disclosure: When you buy through our links, we may earn a commission. We also include products that we do not earn a commission from.

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