DIY Tonneau Repairs? Anyone try to do this yet?

[Lil'O Annie]

I think a dual motor setup would introduce more of an issue specifically as it comes to syncronization. Both would have to be perfectly timed, the second one falls out of sync with the other, same issue.

I thought of that, too. And, it would add extra costs. Not sure just how to design the perfect setup for a power tonneau.

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[MNLightning]

Not opening the cover all the way sounds reasonable, but can you help me understand the logic? Is it that winding up the final few panels creates more chance for uneven resistance side to side, and then overlap/sticking?

I'm just guessing that by what I saw in the picture that the cogs aren't engaged fully or at all when fully opened. And if one side is just 1 tooth off you will have an alignment problem.

 

[Zoidz]

I'm just guessing that by what I saw in the picture that the cogs aren't engaged fully or at all when fully opened. And if one side is just 1 tooth off you will have an alignment problem.

Agree, it's not an issue of one motor vs. two. The jackshaft design for powering both sides with one motor is reasonable. It appears to me that the cog wheel engages in a "linear rack" on the underside of each slat. A big variation in friction on one side is probably causing it to skip and skew the panel, and jam.

If that's how it works, it's an elegant but not very robust design. Too many tolerance variations under too many varying environmental conditions.

 

[MNLightning]

One thing though, if it's happening on the closing function..And it's jumping off on one side then that might be a clearance/binding issue. But I'd think it would have to be pretty darn stuck to jump a tooth while closing.

Thankfully I haven't had an issue.

 

[Zoidz]

...
But I'd think it would have to be pretty darn stuck to jump a tooth while closing.
...

Or the manufacturing/assembly tolerances are so sloppy it skips under anything other than almost perfect conditions.......

 

[RivianXpress]

Thanks so much!
If this were to bind out in the field how long do you think it would take to remove the panels to open it all the way? Can you mention which exact tools were needed?

I’m worried that this may happen on one of my dirt bike trips and bring unable to load bikes would be a huge problem. I’d like to carry the tools ? just in case.
Seems they should have a release pull to disengage so you could retract the cover if it was binding.

 

[crashmtb]

A 2x4 and some whacks with a dead blow hammer on the left side would be my first attempt. "Hold my beer!".

“It’s ok, I’m an engineer!” Is one of the scariest things to hear

 

[Lil'O Annie]

Thanks so much!
If this were to bind out in the field how long do you think it would take to remove the panels to open it all the way? Can you mention which exact tools were needed?

I’m worried that this may happen on one of my dirt bike trips and bring unable to load bikes would be a huge problem. I’d like to carry the tools ? just in case.
Seems they should have a release pull to disengage so you could retract the cover if it was binding.

Wow...I understand your concern!!
You need a set of star-bits with a ratchet. There is a tight spot under the window corners where you'll need a 1/4 wrench for the star bit to reach a star screw that you can't reach with the ratchet attached. Need 8mm & 10mm sockets. Pliers, flat-head screwdrivers (tiny to large). Nothing too specialized, but not everyone may have star bits.
Biggest item is patience and a bit of finesse to gently remove/reset covers. Be sure to document the entire removal process, so you know how to put it back together (we didn't document the whole thing, but wish we had. Did have enough to get things back together, though).
It took us all afternoon, probably 4-5 hours, but we had to explore and analyze the situation as we went. If you knew exactly what you were doing, would probably take 2-3 hours. We went slowly and carefully to avoid breaking anything.

 

[RivianXpress]

Wow...I understand your concern!!
You need a set of star-bits with a ratchet. There is a tight spot under the window corners where you'll need a 1/4 wrench for the star bit to reach a star screw that you can't reach with the ratchet attached. Need 8mm & 10mm sockets. Pliers, flat-head screwdrivers (tiny to large). Nothing too specialized, but not everyone may have star bits.
Biggest item is patience and a bit of finesse to gently remove/reset covers. Be sure to document the entire removal process, so you know how to put it back together (we didn't document the whole thing, but wish we had. Did have enough to get things back together, though).
It took us all afternoon, probably 4-5 hours, but we had to explore and analyze the situation as we went. If you knew exactly what you were doing, would probably take 2-3 hours. We went slowly and carefully to avoid breaking anything.

Thank you!

 

[crashmtb]

Or the manufacturing/assembly tolerances are so sloppy it skips under anything other than almost perfect conditions.......

An easy fix might be a UHMW(or similar) guide above the gears, so that when the slat approaches/is on top of the gear it’s held down and can’t jump off.

theres probably something like that in the cover already, but not enough.

 

[Lil'O Annie]

Here's a few photos of the undersides of the tonneau panels to help you understand more about how these work. The edge-teeth on the panels are metal with a plastic coating, so seem fairly substantial.
I'm not sure why there are exposed areas of metal on the edges (last photo). I didn't scratch the coating off...they were that way when we pulled them out of the railings. Either they chipped off during use or were that way when installed.
And, I should mention, I didn't notice any chipping of the plastic coating on the panel teeth shown in these photos. Didn't get a chance to inspect all the panels in the set that remained in the box stack, however.

 

[R_1_T]

Here's a few photos of the undersides of the tonneau panels to help you understand more about how these work. The edge-teeth on the panels are metal with a plastic coating, so seem fairly substantial.
I'm not sure why there are exposed areas of metal on the edges (last photo). I didn't scratch the coating off...they were that way when we pulled them out of the railings. Either they chipped off during use or were that way when installed.
And, I should mention, I didn't notice any chipping of the plastic coating on the panel teeth shown in these photos. Didn't get a chance to inspect all the panels in the set that remained in the box stack, however.

Certainly looks like the design is destined to fail based on the wear patterns. Materials aren't durable enough to hold up against any grit destined to get in, and side to side tolerances might also be an issue based on the wear to the "panel end caps with the rack gear teeth. Finally, the end caps are being pulled out of the panel when they get tweaked. Once this happens it will certainly continue to bind up and stop moving.

 

[crashmtb]

Here's a few photos of the undersides of the tonneau panels to help you understand more about how these work. The edge-teeth on the panels are metal with a plastic coating, so seem fairly substantial.
I'm not sure why there are exposed areas of metal on the edges (last photo). I didn't scratch the coating off...they were that way when we pulled them out of the railings. Either they chipped off during use or were that way when installed.
And, I should mention, I didn't notice any chipping of the plastic coating on the panel teeth shown in these photos. Didn't get a chance to inspect all the panels in the set that remained in the box stack, however.

Interesting, do all of the slats alternate white/black like that?
the coating that isn’t completely covering things is probably to reduce friction on the sliding parts and gear teeth.

 

[CommodoreAmiga]

I'm a bit perplexed (and concerned) with how many failures we're still seeing. I would have thought Rivian would have done a LOT of durability testing on the powered tonneau. It was a heavily marketed feature, and generally considered to be a "differentiator" from the competition. Until recently it was even standard/required equipment on Adventure trim. The tonneau has the potential to dramatically impact perceived brand reliability.

 

[Davethadog]

We think having just one motor on one side will inevitably lead to an uneven slip and misalignment.

You only need one source of power. You do need a rigid way of indexing each side.

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