Alu Bundu Canopy by Hannes Thirion

I bought my 2001 Toyota Hilux KZ-TE with a fibre glass canopy that was not dust or water proof. The vehicle looked more like a MAV (mall assault vehicle) than an overland vehicle.

I did start to look around for a suitable alternative that was dustproof and strong enough to fit a RTT. The best solution was an aluminium canopy. Those available in the market are very expensive. I did asked around, and with the help and motivation that I received on the Overland Forum, decided to design and built my own alu bundu canopy. The end result is a homemade functional alu bundu canopy that is dust and water proof.

The planning and design of the canopy did take some time.

I bought a mitre with which I cut the sections of the frame at specific angles, 45°, 67° and 90°.

I traced the profile of the cab of the bakkie on a large enough carton. From the sketch on the carton I worked out the angles and the length of sections of the frame.

I needed someone who could do aluminium welding for me at a reasonable price. I did phone around and got hold of Aluminium & Stainless Steel Welding (012) 546-8061 in Pretoria North. They did an excellent job.

With the frame ready, I could start fitting the aluminium ‘trapplaat’ with rivets and silicon sealant on the frame. The aluminium was bought at Non-Ferrous Metal Works tel (012) 327-0016 and Mecawa Sales (012) 661-2260. Rivets and silicon sealant was bought at Chamberlains (012) 998-5074.

The roof of the canopy is 3mm ‘trapplaat’, and the rest 1.5mm.

Aluminium angle iron (25mm x 1.5mm) was fitted over all the corners with rivets and silicon to ensure a smooth solid finish.

The final result is an alu bundu canopy that is strong, light and functional.

My wife made a bag that tie to the inside of the kitchen box of the canopy to hold the cutlery etc. Marine plywood was fitted on the work-surface.

A rack was fitted in the top half of the canopy to accommodate long stuff, i.e. the gazebo, folding chairs etc.

The big rear door gives easy access to the slider for the fridge and food container.

The door on the right is supported by a gas strut to give easy access to a rack for two low lid ammo cases and the large top rack for chairs etc.

Hinges, door handles and rubbers were bought at Silverton Canopy Centre (012) 804-1271.

The alu bundu canopy was tested at Serendipity.

Now I can really explore all those lovely places off the beaten track!

Material list and prices ( April 2006) Sq Tube 25 x 3mm (frame) 24m R 600.00 Rect Tube 40 x 20 x 1.2mm (doors) 18m R 255.00 Flat 38 x 3mm 15m R 195.00 Angle 25 x 1.5mm 36m R 312.00 Vastrapplaat 3mm (roof) 1160 x 1400mm R 663.49 Vastrapplaat 1.5mm (sides) 7690 x 3340mm R1,066.00 Sub Total R 3,091.67 Alu welding R20/joint R 1,580.00 Door rubbers 14m R 141.06 Canopy connectors 4 R 80.00 Gas lift 2 R 240.00 hinges (s/steel) 12 R 282.12 Toggles 6 R 137.40 Rivets R 119.50 Silicon sealant R 230.45 R 1,230.53 R 5,902.20

Contact detail of suppliers Non-Ferrous Metal Works tel (012) 327-0016 - aluminium Mecawa Sales (012) 661-2260 - aluminium Aluminium & Stainless Steel Welding (012) 546-8061 – aluminium welding Silverton Canopy Centre (012) 804-1271 – hinges, toggles, rubbers etc. Chamberlains (012) 998-5074 – rivets and silicon sealant