---

Hi everyone,

I'm trying to design a pickup truck canopy for the KMC T9 in SOLIDWORKS. My boss told me that if I can successfully design this canopy, he'll hire me.

I'm having a serious problem with the rear frame (highlighted in the image). The canopy is made from sheet metal, so all the geometry has to remain manufacturable and flatten correctly.

To create the rear frame, I used Swept Boss/Base and then converted it to Sheet Metal. The top surface comes out correctly and stays horizontal (90° to the side faces), but the side faces become distorted. Their angles change and some dimensions are no longer consistent or "square." Because of that, I can't model the side panels correctly since they no longer match the rear frame.

Has anyone dealt with this kind of geometry before?

Is Swept Boss/Base + Convert to Sheet Metal the wrong workflow?

Is there a better method to create this kind of tapered rear frame while keeping all the angles accurate?

How would you model this so it's suitable for sheet metal manufacturing?

Any advice or a recommended workflow would be greatly appreciated. Thanks!

 The red outline in the image highlights the rear frame I'm referring to.

Finding a job in Iran is extremely difficult, and this opportunity means a lot to me. I'm in a tough situation, so if anyone can help me figure this out, I would be sincerely grateful. Thank you so much.