Does a Truck Bed Cover Help MPG? Benefits, Types, and Real-World Fuel Economy Insights

Introduction

You’re standing at the gas pump watching the numbers climb—again—and wondering if there’s any practical way to improve your pickup truck’s fuel economy without sacrificing utility. You’ve heard claims that a tonneau cover can boost gas mileage, but with covers ranging from $200 to over $1,000, you want to know: does a truck bed cover help MPG enough to justify the investment?

The answer isn’t a simple yes or no. The fuel economy impact of tonneau covers depends on multiple factors including cover type, driving conditions, truck model, and even how you drive. While manufacturers and some studies claim fuel savings of 5-10%, real-world results often tell a more nuanced story. Understanding the aerodynamics, weight considerations, and practical driving scenarios helps separate marketing hype from measurable benefits.

Pickup trucks are inherently less aerodynamic than passenger cars, with the open bed creating significant drag at highway speeds. This aerodynamic disadvantage translates directly to reduced fuel efficiency—especially once you exceed 50-55 mph where wind resistance becomes the dominant force your engine must overcome. In theory, covering that open bed should smooth airflow, reduce drag, and improve miles per gallon. But does the theory hold up in practice?

In this comprehensive guide, we’ll examine the science behind tonneau cover fuel economy improvements, review independent studies and wind tunnel results, compare different cover types (hard vs. soft, folding vs. rolling), and most importantly, share real-world mpg data from actual truck owners. Whether you’re considering a hard folding cover, a soft roll-up, or a retractable tonneau, you’ll learn exactly what fuel savings to expect, how driving conditions affect results, and whether the investment makes financial sense for your specific situation. Let’s separate fact from fiction and help you make an informed decision about this popular truck accessory.

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Understanding Truck Bed Aerodynamics and Fuel Economy

Before diving into specific tonneau covers, let’s understand why pickup trucks struggle with fuel efficiency and how bed covers theoretically address the problem.

The Aerodynamic Challenge of Pickup Trucks

Why Trucks Are Fuel-Inefficient:

Pickup trucks face unique aerodynamic challenges compared to cars and SUVs:

The Open Bed Problem:

• Creates a large cavity that disrupts smooth airflow
• Air flowing over the cab hits the bed wall, creating turbulence
• Swirling vortices form inside the bed
• This turbulent air increases drag coefficient significantly
• Additional drag force requires more engine power to maintain speed

Drag Coefficient Basics:

Coefficient of Drag (Cd):

• Measures how easily air flows around a vehicle
• Lower numbers = better aerodynamics = better fuel economy
• Passenger cars: Cd 0.25-0.35
• Full-size pickup trucks (bed open): Cd 0.45-0.55
• Pickup trucks (with tonneau): Cd 0.40-0.48

Real-World Impact:

At highway speeds:

• 50 mph: Aerodynamic drag becomes significant
• 65 mph: Drag force roughly doubles compared to 50 mph
• 75 mph: Aerodynamic drag dominates fuel consumption
• Each 5 mph increase above 50 mph reduces fuel economy by approximately 7%

The Truck Bed as a Parachute:

Think of an open truck bed at highway speeds:

• Acts like a parachute catching air
• Creates low-pressure zone behind the cab
• High-pressure air in front pushes against vehicle
• Turbulent air in bed creates additional resistance
• Your engine works harder fighting this invisible force

How Tonneau Covers Improve Aerodynamics

The Theory:

A tonneau cover theoretically improves fuel efficiency by:

Smoothing Airflow:

• Creates smooth surface over truck bed
• Air flows over cover instead of into bed cavity
• Reduces turbulence and vortex formation
• Allows air to reattach to truck surface more smoothly
• Decreases overall drag coefficient

Pressure Management:

• Reduces pressure differential between front and rear
• Minimizes low-pressure vacuum effect behind cab
• Creates more streamlined profile
• Allows air to flow off rear more efficiently

Wind Tunnel Results:

Independent testing shows:

• Drag reduction: 5-15% with tonneau cover
• Variation depends on cover type and truck model
• Hard covers generally show better results than soft covers
• Flush-mounted covers perform better than raised covers

Important Caveat:

These percentages represent drag reduction, not direct mpg improvement. The relationship between drag and fuel consumption isn’t 1:1, especially since:

• Aerodynamic drag is just one component of total resistance
• Other factors (weight, rolling resistance, drivetrain efficiency) also matter
• Highway driving shows more benefit than city driving
• Actual mpg gains are typically smaller than drag reduction percentages

Highway vs. City Driving: Where Covers Matter Most

Highway Driving (55+ mph):

This is where tonneau covers provide measurable benefit:

Why Highway Matters:

• Aerodynamic drag increases exponentially with speed
• At 65 mph, aerodynamics account for 50-60% of resistance
• At 75 mph, aerodynamics dominate fuel consumption
• Reducing drag has significant impact

Expected Highway Gains:

• 0.5-2.0 mpg improvement at 65-70 mph
• Percentage gain: 2-8% depending on baseline mpg
• More noticeable on longer highway trips
• Greater benefit at higher speeds (75+ mph)

City Driving (Under 45 mph):

Tonneau covers provide minimal benefit in urban driving:

Why City Shows Little Improvement:

• Constant acceleration/deceleration dominates fuel use
• Speeds too low for aerodynamics to matter significantly
• Stop-and-go driving negates aerodynamic benefits
• Weight of cover may actually reduce efficiency slightly

Expected City Gains:

• 0-0.3 mpg improvement (often within measurement error)
• Essentially negligible in real-world driving
• Other factors (driving habits, traffic) far more important

Mixed Driving Reality:

Most truck owners experience:

• Combination of highway and city driving
• Overall mpg improvement: 0.5-1.5 mpg typically
• Percentage improvement: 2-5% in mixed conditions
• More highway driving = more noticeable benefit

The Weight Factor: Does It Cancel Out Aerodynamic Gains?

Tonneau Cover Weights:

Different cover types add varying amounts of weight:

Soft Roll-Up Covers:

• Weight: 25-40 pounds
• Minimal impact on fuel economy
• Lightest option available

Soft Folding Covers:

• Weight: 40-60 pounds
• Still relatively light
• Moderate aerodynamic benefit

Hard Folding (Aluminum):

• Weight: 50-80 pounds
• Good balance of weight and aerodynamics
• Most popular choice

Hard Folding (Fiberglass):

• Weight: 70-110 pounds
• Heavier but excellent aerodynamics
• Best drag reduction

Retractable Covers:

• Weight: 80-150 pounds
• Heaviest option
• Excellent aerodynamics but weight penalty

Weight Impact on Fuel Economy:

The Math:

• Every 100 pounds reduces mpg by approximately 1-2%
• A 60-pound tonneau reduces mpg by roughly 0.12-0.24 mpg
• Aerodynamic benefit must exceed weight penalty to show net gain

Net Effect:

For most covers:

• Aerodynamic gain: +0.5 to +2.0 mpg (highway)
• Weight penalty: -0.1 to -0.3 mpg (all driving)
• Net benefit: +0.4 to +1.7 mpg (highway conditions)

When Weight Matters Most:

• Short trips with frequent acceleration
• Mountainous terrain (climbing hills)
• Heavy hauling (added to existing load)
• City driving where aerodynamics don’t help

Best Practice:

Choose lighter covers if:

• Primarily city driving
• Frequent hauling of heavy loads
• Concerned about every pound

Choose heavier covers if:

• Primarily highway driving
• Want maximum security and durability
• Aerodynamic benefit outweighs weight concern

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Types of Truck Bed Covers and Their MPG Impact

Not all tonneau covers are created equal when it comes to fuel efficiency. Let’s examine how different designs affect aerodynamics and fuel economy.

Hard Folding Tonneau Covers

Design Characteristics:

Hard folding covers typically feature:

• 2-4 rigid panels (aluminum, fiberglass, or composite)
• Fold up against cab for bed access
• Flush or low-profile mounting
• Weatherproof seals
• Lockable security

Aerodynamic Performance:

Pros:

• Rigid surface creates smooth airflow
• Minimal gap between panels when closed
• Flush-mounted designs minimize height
• Excellent drag reduction (7-12% in tests)
• Maintains aerodynamic profile at speed

Estimated Fuel Economy Impact:

Highway (65-70 mph):

• Improvement: 1.0-2.0 mpg
• Percentage gain: 4-8%
• Most noticeable at sustained speeds

City Driving:

• Improvement: 0-0.3 mpg
• Essentially negligible

Mixed Driving:

• Improvement: 0.5-1.2 mpg
• Overall: 2-5% better fuel economy

Popular Hard Folding Models:

• BAKFlip MX4
• UnderCover Armor Flex
• Extang Solid Fold 2.0
• Gator ETX

Weight Consideration:

• Aluminum: 50-70 pounds
• Fiberglass: 70-100 pounds
• Trade-off: Better aerodynamics vs. added weight

Best For:

• Highway commuters
• Those prioritizing fuel savings
• Owners wanting security and weather protection
• Long-distance travelers

Soft Roll-Up Tonneau Covers

Design Characteristics:

Soft roll-up covers feature:

• Vinyl or canvas material
• Roll toward cab or into canister
• Lightweight construction
• Lower cost option
• Velcro or snap closure

Aerodynamic Performance:

Pros:

• Still smooths bed airflow
• Lightweight (minimal weight penalty)
• Cost-effective

Cons:

• May flutter or balloon at speed
• Less smooth surface than hard covers
• Potential air gaps in closure
• Moderate drag reduction (4-8% in tests)

Estimated Fuel Economy Impact:

Highway (65-70 mph):

• Improvement: 0.5-1.2 mpg
• Percentage gain: 2-5%
• Less consistent than hard covers

City Driving:

• Improvement: 0-0.2 mpg
• Negligible benefit

Mixed Driving:

• Improvement: 0.3-0.8 mpg
• Overall: 1-3% better fuel economy

Popular Soft Roll-Up Models:

• TruXedo Lo Pro
• Access Roll-Up
• MaxMate Soft Roll-Up
• Tyger Auto T1

Advantages:

• Lightest option (25-40 pounds)
• Lowest cost ($200-400)
• Easy DIY installation
• Simple operation

Best For:

• Budget-conscious buyers
• Occasional highway drivers
• Those wanting minimal weight addition
• Ease of use priority over maximum fuel savings

Three-Fold and Retractable Covers

Three-Fold Soft Covers:

Characteristics:

• Three fabric panels
• Fold up against cab
• Middle ground between roll-up and hard folding
• Better aerodynamics than roll-up
• Weight: 40-60 pounds

Fuel Economy:

• Highway improvement: 0.7-1.5 mpg
• Mixed driving: 0.4-1.0 mpg
• Better than roll-up, slightly less than hard folding

Retractable Hard Covers:

Characteristics:

• Rigid slats that roll into canister
• Excellent aerodynamics when closed
• Premium pricing ($800-1,500)
• Weight: 80-150 pounds
• Low-profile design

Fuel Economy:

Pros:

• Excellent drag reduction (8-12%)
• Flush-mounted for optimal airflow
• Highway improvement: 1.0-2.0 mpg

Cons:

• Heavy (weight penalty reduces net gain)
• Canister takes some bed space
• Net improvement similar to lighter hard-folding covers

Estimated Net Gain:

• Highway: 0.8-1.5 mpg (accounting for weight)
• Mixed: 0.4-1.0 mpg

Comparison Table: Cover Types and Fuel Economy

Quick Reference:

Cover Type	Weight	Cost	Highway MPG Gain	City MPG Gain	Best For
Hard Folding	50-80 lbs	$600-1,200	1.0-2.0 mpg	0-0.3 mpg	Highway commuters
Soft Roll-Up	25-40 lbs	$200-400	0.5-1.2 mpg	0-0.2 mpg	Budget buyers
Three-Fold Soft	40-60 lbs	$300-600	0.7-1.5 mpg	0-0.3 mpg	Balanced needs
Retractable Hard	80-150 lbs	$800-1,500	0.8-1.5 mpg	0-0.2 mpg	Premium features

Key Insights:

1. Hard covers generally outperform soft covers for aerodynamics
2. Weight differences partially offset aerodynamic gains
3. All covers show minimal city driving benefit
4. Highway driving at 65+ mph is where benefits appear
5. Price doesn’t always equal fuel savings (heavy retractable vs. light hard-folding)

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Real-World MPG Data and Studies

Theory and manufacturer claims are one thing—what do actual tests and truck owners report?

Independent Wind Tunnel and Road Tests

SEMA (Specialty Equipment Market Association) Study:

One of the most-cited studies tested multiple tonneau covers:

Test Conditions:

• Full-size pickup truck in wind tunnel
• Various cover types tested
• Baseline: uncovered bed
• Measured drag coefficient changes

Results:

• Soft roll-up cover: 5-7% drag reduction
• Hard three-fold: 8-10% drag reduction
• Hard flush-mounted: 10-12% drag reduction
• Bed cover + tailgate up: Best performance
• No cover + tailgate down: Actually WORSE than tailgate up

Key Finding:

The myth that lowering your tailgate improves fuel economy is FALSE. Tailgate up creates better airflow management than tailgate down.

Automotive Authority Magazine Test:

Real-world highway testing with GPS fuel economy tracking:

Test Vehicle: 2019 Ford F-150 5.0L V8

Baseline 

• Highway MPG: 20.8 mpg

With Hard Folding Cover:

• Highway MPG: 21.9 mpg
• Improvement: 1.1 mpg (5.3%)

With Soft Roll-Up:

• Highway MPG: 21.3 mpg
• Improvement: 0.5 mpg (2.4%)

Test Conditions:

• 200-mile highway loop
• Cruise control at 70 mph
• Same weather conditions
• Multiple test runs averaged

Consumer Reports Analysis:

Their testing showed more modest results:

Findings:

• Highway improvement: 0.5-1.5 mpg typical
• City improvement: Negligible to none
• Combined cycle: 0.3-1.0 mpg average
• Results varied significantly by truck model
• Newer trucks showed less improvement (already more aerodynamic)

Mythbusters Episode:

The popular show tested tonneau covers:

Their Test:

• 2008 Dodge Ram 1500
• 100-mile highway loop
• Multiple configurations

Results:

• Tonneau cover: Small but measurable improvement
• Tailgate down: WORSE than tailgate up
• Confirmed manufacturers’ claims were in the right ballpark
• Improvement: Approximately 1 mpg at highway speeds

User-Reported MPG Improvements

Online Forum Data Analysis:

Compilation of user reports from truck forums (F150Forum, RAM Forum, Silverado1500):

Sample Size: 200+ owners reporting before/after data

Average Reported Improvements:

Highway-focused drivers (70%+ highway miles):

• 1.0-2.5 mpg improvement reported
• Range: 4-10% better fuel economy
• Hard covers showed better results
• Consistent high-speed driving showed most benefit

Mixed driving (50/50 highway/city):

• 0.5-1.2 mpg improvement reported
• Range: 2-5% better fuel economy
• Highly variable results
• Some reported no noticeable change

City-focused drivers (70%+ city miles):

• 0-0.5 mpg improvement
• Most couldn’t detect measurable benefit
• Within measurement error for many
• Other factors had bigger impact

Skeptical Reports:

Not all users saw benefits:

• 15-20% reported no improvement
• Some reported slight decrease (possible weight effect)
• Measurement difficulties (fuel gauge accuracy, driving variations)
• Tank-to-tank variability makes small changes hard to detect

Most Reliable Reports:

Best user data came from:

• Long-term testing (multiple months)
• GPS-based fuel tracking apps
• Highway-heavy driving patterns
• Careful before/after comparison
• Multiple tank averages

Case Studies: Real Truck Owners

Case Study 1: Long-Distance Commuter

Profile:

• Vehicle: 2020 Chevrolet Silverado 1500 5.3L
• Driving: 80 miles/day highway commute
• Cover: BAKFlip MX4 (hard aluminum folding)

Results After 6 Months:

Before cover:

• Average MPG: 21.3 mpg (highway-heavy)
• Annual fuel cost: $2,840 (15,000 miles)

After cover:

• Average MPG: 22.4 mpg
• Improvement: 1.1 mpg (5.2%)
• Annual fuel cost: $2,700
• Annual savings: $140

Owner’s assessment: “The cover paid for itself in fuel savings after about 5 years, but I bought it mainly for security and weather protection. The mpg boost was a nice bonus. Most noticeable on long highway trips at 70-75 mph.”

Case Study 2: Mixed Driving Suburban Owner

Profile:

• Vehicle: 2021 RAM 1500 3.6L V6
• Driving: 60% city, 40% highway
• Cover: TruXedo Lo Pro (soft roll-up)

Results After 3 Months:

Before cover:

• Average MPG: 18.7 mpg (mixed)

After cover:

• Average MPG: 19.1 mpg
• Improvement: 0.4 mpg (2.1%)
• Hard to distinguish from normal variation

Owner’s assessment: “I can’t honestly say I notice a fuel economy difference in my normal driving. The cover’s main value is keeping my bed dry and looking cleaner. Any fuel savings are a small bonus, not the reason to buy it.”

Case Study 3: City Driver Sees No Benefit

Profile:

• Vehicle: 2019 Ford F-150 2.7L EcoBoost
• Driving: 75% city, 25% short highway
• Cover: Extang Solid Fold 2.0 (hard folding)

Results After 4 Months:

Before cover:

• Average MPG: 17.8 mpg (city-heavy)

After cover:

• Average MPG: 17.7 mpg
• Improvement: -0.1 mpg (within error margin)

Owner’s assessment: “Zero fuel economy benefit in my mostly city driving. I bought it for bed protection and theft deterrence. If you’re hoping for better gas mileage in stop-and-go traffic, don’t count on it.”

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Pros and Cons: Is a Tonneau Cover Worth It for MPG?

Let’s weigh the advantages and disadvantages of installing a tonneau cover specifically for fuel economy benefits.

Advantages of Tonneau Covers for Fuel Efficiency

Proven Highway Fuel Savings:

Measurable Benefit:

• 0.5-2.0 mpg at highway speeds (most see 1.0-1.5 mpg)
• 2-8% improvement in highway fuel economy
• More noticeable at speeds above 65 mph
• Consistent across multiple independent tests

Financial Calculation:

For a highway commuter driving 15,000 miles/year:

• Baseline: 20 mpg, fuel at $3.50/gallon
• Annual cost: $2,625
• With 1.5 mpg improvement: 21.5 mpg
• New annual cost: $2,442
• Annual savings: $183

Payback period for $700 cover: 3.8 years

Cumulative Benefits:

Over 10 years of ownership:

• Total fuel savings: $1,830
• Cover cost: $700
• Net benefit: $1,130
• Plus resale value of cover

Multiple Benefits Beyond Fuel:

Tonneau covers provide additional value:

Security:

• Conceals cargo from thieves
• Lockable covers prevent theft
• Peace of mind for tools and equipment

Weather Protection:

• Keeps bed dry
• Protects cargo from rain, snow, sun
• Prevents rust in bed

Aesthetics:

• Sleeker appearance
• Improves truck’s profile
• Higher perceived value

Cargo Management:

• Prevents items from blowing out
• Reduces road spray into bed
• Keeps bed cleaner

Resale Value:

Quality covers can:

• Increase truck resale value
• Transfer to new owner
• Demonstrate good maintenance
• Typically recover 30-50% of purchase price

Disadvantages and Limitations

Modest Fuel Savings in Real-World Mixed Driving:

Reality Check:

Most truck owners experience:

• Mixed city/highway driving
• Overall improvement: 0.5-1.0 mpg typically
• Percentage: 2-4% in combined driving
• Often hard to measure tank-to-tank
• Other factors (weather, load, driving style) create variation

Long Payback Period:

Financial Reality:

For moderate drivers (12,000 miles/year, 50/50 city/highway):

• Fuel savings: $80-120/year
• Cover cost: $400-1,200
• Payback: 3-10 years
• Must keep truck long-term to realize savings

Not Worth It for Fuel Alone (Usually):

If fuel economy is your ONLY reason:

• Consider other modifications first (tires, maintenance, driving habits)
• Math doesn’t strongly favor purchase for fuel savings alone
• Better justification: multiple benefits combined

Negligible City Driving Benefit:

Urban Drivers:

If you primarily drive in city:

• Expect 0-0.3 mpg improvement
• Essentially unmeasurable
• Weight of cover may offset any gain
• Better ways to improve city mpg exist

Weight Penalty:

Heavier Covers:

Retractable and heavy fiberglass covers:

• 100-150 pound weight addition
• Reduces fuel economy by 0.2-0.3 mpg from weight alone
• Partially offsets aerodynamic gain
• Net benefit reduced compared to lighter covers

Access Limitations:

Practical Considerations:

• Takes time to open/close for bed access
• May interfere with tall cargo
• Some covers incompatible with bed racks
• Reduced bed utility compared to fully open bed

The Verdict: When Tonneau Covers Make Sense for MPG

Buy a tonneau cover primarily for fuel savings if:

✓ You drive primarily highway miles (60%+) ✓ You frequently drive at speeds above 60 mph ✓ You plan to keep your truck for 5+ years ✓ You want multiple benefits (security, weather protection, appearance) ✓ You value the cumulative small savings over time

Don’t buy a tonneau cover only for fuel savings if:

✗ You drive mostly city miles ✗ Your annual mileage is low (under 10,000 miles) ✗ You frequently haul tall cargo ✗ You expect dramatic fuel economy transformation ✗ You need immediate payback on investment

Best Approach:

Consider tonneau covers a multi-benefit upgrade:

• Primary: Security, weather protection, aesthetics
• Secondary: Modest fuel economy improvement
• Bonus: Potential resale value increase

The fuel savings are real but modest—a welcome addition to other benefits rather than the sole justification for purchase.

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Maximizing Fuel Efficiency with Your Tonneau Cover

If you’ve decided to install a cover, optimize its fuel-saving potential with these strategies.

Proper Installation for Maximum Aerodynamic Benefit

Installation Quality Matters:

Poor installation reduces effectiveness:

Key Installation Points:

Flush Mounting:

• Install cover as low/flush as possible
• Minimize height above bed rails
• Follow manufacturer’s torque specifications
• Ensure even positioning side-to-side

Seal Quality:

• Proper weatherstripping installation
• No gaps between cover and bed rails
• Tailgate seal must be intact
• Check for air leaks at speed

Secure Fastening:

• Tighten all clamps properly
• Prevent cover flutter at highway speeds
• Loose covers can increase drag instead of reducing it
• Periodic checks for tightness

Professional vs. DIY:

DIY Installation:

• Most covers designed for homeowner installation
• 30-90 minutes typical install time
• Follow instructions carefully
• Torque specifications matter

Professional Installation:

• Ensures optimal setup
• Cost: $50-150 typically
• Worth it for complex retractable covers
• May void warranty if done wrong

Optimizing Driving Habits

Speed Management:

Aerodynamic benefits increase with speed:

Optimal Speed Range:

• 55-65 mph: Noticeable benefit begins
• 65-75 mph: Maximum percentage improvement
• Above 75 mph: Larger absolute savings but lower overall mpg

Speed vs. MPG:

• Every 5 mph over 50 mph reduces mpg by ~7%
• Tonneau cover doesn’t eliminate this penalty
• Best strategy: Cover + moderate speed (60-65 mph)

Cruise Control Usage:

Benefits:

• Maintains steady speed
• Eliminates acceleration/deceleration
• Maximizes aerodynamic benefits
• Use on highways for best results

Other Fuel-Saving Driving Habits:

Complement your tonneau cover with:

Acceleration:

• Gentle acceleration from stops
• Anticipate traffic flow
• Avoid aggressive driving

Maintenance:

• Proper tire inflation (check monthly)
• Regular air filter changes
• Quality motor oil
• Wheel alignment

Load Management:

• Remove unnecessary weight from bed
• Don’t carry tools/equipment you don’t need
• Every 100 pounds costs 1-2% fuel economy

Trip Planning:

• Combine errands
• Avoid peak traffic times
• Plan efficient routes
• Use GPS to avoid congestion

Complementary Modifications

Other Aerodynamic Improvements:

Combine with tonneau cover for maximum benefit:

Air Dam/Front Spoiler:

• Reduces air going under truck
• Works synergistically with tonneau cover
• Fuel improvement: 0.3-0.8 mpg additional

Bed Cap/Topper:

• Even better aerodynamics than tonneau
• Full enclosure eliminates turbulence
• Trade-off: Reduced bed accessibility
• Fuel improvement: 1.5-3.0 mpg (more than tonneau)

Tire Selection:

• Low rolling resistance tires
• Proper size (don’t upsize unnecessarily)
• Fuel improvement: 0.5-1.5 mpg

Avoid Counterproductive Mods:

• Lift kits (increase drag)
• Oversized tires (hurt mpg significantly)
• Bull bars and brush guards (add drag)
• Roof racks when not needed (major drag penalty)

Maintenance and Longevity

Keeping Your Cover Effective:

Regular Maintenance:

Monthly:

• Check all fasteners and clamps
• Inspect seals for wear
• Clean cover surface
• Verify no air gaps

Seasonally:

• Lubricate hinges and moving parts
• Check drainage system
• Inspect for cracks or damage
• Re-torque fasteners if needed

Cover Lifespan:

Expected Durability:

• Soft vinyl: 3-7 years
• Aluminum hard covers: 10-15 years
• Fiberglass: 10-20 years
• Retractable: 7-12 years

Maintaining Aerodynamic Performance:

• Clean regularly (dirt increases drag)
• Repair damage promptly
• Replace worn seals
• Keep cover closed when driving

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Frequently Asked Questions

Does a tonneau cover really help with gas mileage?

Yes, tonneau covers do improve gas mileage, but the improvement is modest and primarily occurs during highway driving. Independent tests and real-world data show highway fuel economy improvements of 0.5-2.0 mpg (2-8%) at speeds above 60 mph. Hard covers generally perform better than soft covers. However, city driving shows minimal to no measurable benefit. The aerodynamic advantage of covering the truck bed reduces drag, which translates to less engine work at highway speeds, resulting in measurable but not dramatic fuel savings.

How much MPG can a tonneau cover save?

Based on real-world testing and user reports, you can expect:

• Highway driving (65-70 mph): 1.0-2.0 mpg improvement
• Mixed driving (50/50 city/highway): 0.5-1.2 mpg improvement
• City driving: 0-0.3 mpg improvement (essentially negligible)

The exact amount depends on your specific truck model, cover type, driving speed, and conditions. For most truck owners with typical mixed driving, expect around 0.5-1.5 mpg overall improvement, or roughly 2-5% better fuel economy. Hard folding covers tend to show better results than soft roll-up covers.

Do hard folding tonneau covers give more fuel economy than soft ones?

Does a truck bed cover  help MPG? Yes, hard folding tonneau covers typically provide better fuel economy benefits than soft roll-up covers. Wind tunnel tests show:

• Hard covers: 8-12% drag reduction
• Soft covers: 4-8% drag reduction

This translates to approximately 0.2-0.5 mpg more improvement with hard covers in real-world highway driving. The rigid surface of hard covers creates smoother, more consistent airflow with fewer gaps and less flutter at speed. However, hard covers also weigh more (50-80 lbs vs. 25-40 lbs), which partially offsets the aerodynamic advantage. For maximum fuel savings, choose a lightweight hard aluminum cover rather than heavy fiberglass.

Will a tonneau cover improve fuel efficiency at highway speeds?

Yes, highway speeds are where tonneau covers demonstrate their clearest fuel efficiency benefits. At speeds above 55-60 mph, aerodynamic drag becomes the dominant force your engine must overcome, accounting for 50-60% of total resistance at 65 mph. A tonneau cover’s aerodynamic improvements are most effective in these conditions, with typical highway improvements of 1.0-2.0 mpg. The benefit increases at higher speeds—you’ll see more improvement at 70 mph than at 55 mph. For highway commuters and long-distance drivers, a tonneau cover makes the most sense from a fuel economy perspective.

Does the weight of a tonneau cover negate the fuel savings?

The weight does reduce fuel economy slightly, but the aerodynamic benefits typically outweigh the weight penalty, especially during highway driving. Here’s the math:

• Weight penalty: Every 100 lbs reduces mpg by ~1-2%, so a 60-lb cover costs about 0.1-0.2 mpg
• Aerodynamic gain: Highway driving improvement of 0.5-2.0 mpg
• Net benefit: +0.4 to +1.8 mpg (highway driving)

The heaviest covers (retractable designs at 100-150 lbs) show the smallest net gains because weight penalties are larger. Lightweight soft covers and aluminum hard covers offer the best weight-to-aerodynamic-benefit ratio