I'm cheap and lazy, that means (in my own mind) I'm resourceful. Here's how to build a good-quality awning for less than $100. I was mostly drunk when I built this and it was dark so I forgot to take pictures. Keep in mind you'll need some simple/basic tools - hacksaw, screwdriver, beer fridge, etc...I'll put pictures up tomorrow.
Step 1 - Go Shopping
Get 4 Cheap Coleman Adjustable Tent Poles - These were like $8 at my local Wal-mart...$32
Get a six pack of beer...(not included in price)
Get 2x 10'x3/4" EMT conduit...$8.15 (total $40.15)
Get 4x conduit straps (these are 1" - I can't find a link to the 3/4", so deal with it)...$1.32 (total $41.47)
Get some self-tapping metal screws...$4.98 (total $46.45)
Get some washer...$8.81 (total $55.26)
Get a package of bimini top eye ends...$3.99 (total $59.25)
Get a package of bimini jaw slides...$4.99 (total $64.24)
Order off the internet
Northern Tool 6x8 tarp...$32.99 (total $97.23)
Step 2 - Drink 3 beers (mostly because you didn't do this before and after your done making your supercheap but wicked awesome awning, your going to want to be drunk because you'll realize you are an idiot)
Step 3 - Lay out your tarp
(note, if you want to make this an even cheaper and more ghetto awning, you can use any crappy brown/blue/silver tarp, also sourced from Wal-Mart (see how cool I make it sound by using the word 'sourced'))
Lay out your tarp on a nice flat surface. Make sure it's flat. and nice.
Step 4 - Measure and cut your EMT
Please note: If at any time you hurt yourself and need to call an Emergency Medical Technician, you should NOT cut them. They are the wrong kind of EMT.
Place your EMT at the long end of the tarp, with one end of the tarp lined up with one end of the EMT. Mark the other end of the tarp on the EMT, then add 8" (real inches, not maninches).
Cut the EMT at your tarp+8" mark.
Step 5 - Cut your other EMT (conduit) to the same length.
If you need instructions on how to do this, you are more drunk than I am.
Step 6 - Have another beer
Step 7 - Screw your EMT at both ends
(no...the Electrical Metallic Tubing) Use all those self-tapping screws and washers to secure the EMT to the tarp. Make sure the tarp is centered...the EMT should have some overlap on both sides (a couple of inches). Screw all 5 grommets (and the wallaces too, if you want) into the EMT.
At this point, you should have a tarp, with two EMT conduits screwed down on the long ends of the tarp. You should also have a pretty good buzz.
Step 8 - Attach your fancy boat bimini-top things to the end of your conduit.
Whoa! Getting complicated now. On the conduit that will eventually attach to your roof (rack, etc), take your bimini jaw slides and slide them over the end of the conduit so they are at the end, pointing in the same direction your awning (no longer a tarp) will go)...note: you might have to grind/sand down the inside of the jaw slide to get it to fit over the EMT...or you can pound it with a BFH, or whatever...just get them over the end of the conduit.
Step 9 - Attach your fancy bimini top eye ends to the end of your ghetto Wally World Coleman adjustable tent poles.
These will go on the end with the black rubber thingy (hehe). Take the black rubber thingy off, then attach the bimini top eye ends where it used to be. You'll need an allen wrench. If you don't have an allen wrench, then you should have read these entire instructions before you started.
Step 10 - Attach your tarp/EMT combination to your roof rack.
Use those cool conduit straps to secure the EMT (with the bimini jaw slides) to your roof rack.
Step 11 - Have a beer
Step 12 - Wait...crap...I forgot to drill holes...
To be continued...