Real Answers Q&A With Sr. Industrial Designer Harry Kaloustian: BAKFlip MX4 EZ-Lift MX4 (GEN 3), MX4 TS (GEN 3) Relaunch

At RealTruck, we have an issue with leaving good enough alone. That pursuit of perfection isn’t in vain—it leads us to develop some of the industry's most innovative, proprietary solutions for truck owners’ most-cited headaches.​

Recently, we’ve returned to the drawing board for one of our most popular products—and our best-selling truck bed tonneau cover—the RealTruck® BAKFlip® MX4. With the recent relaunch of the GEN 3 MX4 and T-slot-compatible MX4 TS, the MX4 family was almost complete—it just needed an easier-than-ever younger sibling. Queue the BAKFlip® MX4 EZ-Lift—a torsion-equipped BAKFlip offering an extra-wide paddle handle, lighter feel, and effortless operation.

As the lead editor of RealSource™, I’m always excited to see innovation in action, especially when it raises the bar for truck bed security and utility. I recently chatted with Sr. Industrial Designer, Harry Kaloustian, to learn the key changes to these covers and the philosophy driving this relaunch. Read on for the full Q&A.

Frank Bisciotti (FB): The MX4 has been a market leader for years. What was the "North Star" for the design team when deciding how to evolve the platform for the new EZ-Lift™?

Harry Kaloustian (HK): When we began developing EZ-Lift, our North Star was simple: preserve everything customers love about the MX4 while making it easier to use every day. The MX4 has built its reputation on durability, security, weather resistance, and full bed access, so our focus wasn't on reinventing those strengths; it was on enhancing the ownership experience around them. Every design decision, from the EZ-Lift torsion spring system to the oversized paddle handle, was driven by a goal of reducing effort and improving ergonomics without compromising the performance customers expect.

FB: The standout stat for the EZ-Lift is the 10.5 lbs of lift force—nearly a 3X reduction in effort compared to standard covers. From an engineering perspective, how did you achieve that "weightless" feel?

HK: With some ingenuity from the engineering team, we were able to use a unique torsion spring system between the panels on the underside of the cover that essentially “preloads” the folding action with some force behind it.  

When the cover is flat and closed, these torsion springs and their corresponding rods are under tension that wants to be released in the direction of a panel being opened. That way, all of the folds you make up to the cab window feel just as effortless as the first panel being folded. This makes for a nice experience, especially on a long-bed truck where you need to fold multiple panels at once.

FB: The new XL paddle handle is a massive departure from standard latches. Why was this specific ergonomic change prioritized, and how does it interface with the auto-latch system?

HK: It definitely is! For good reasons, though. We recognized that making a hard-fold cover easier to open isn’t just made possible by torsion springs and the weight reduction they enable, but also by providing an ergonomic way to start the process. The paddle handle is a great solution that activates the latches while still pulling on the cable; however, it gives you a much more comfortable position for your hand.  

FB: Security is a cornerstone of the BAKFlip brand. How did you ensure that the easier-to-operate EZ-Lift system didn't compromise the "Maximum Protection" security level our customers expect?

HK: Security is definitely a prominent feature of the MX4 family, and we recognize that we cannot underdeliver on it. Even with new components on the underside and new handles, we were able to retain mechanisms from our existing latches that have kept the MX4 secure for years. No compromise was made on the hard panels either; they also play a role in security.  

FB: Installation is a huge factor for DIY customers. Have you made any changes to the bolt-on, no-drill installation process?

HK: We actually have not made any changes. This was one of the aspects of the MX4 platform where we saw success, and we didn’t want to alter the positive experience DIY customers are already having.  The bolt-on process remains simple, and there is no need to drill into the truck.  

FB: Full bed access and 3rd brake light visibility are often "either/or" propositions. How did the design team ensure the EZ-Lift maintains 100% bed access without forcing the user to compromise on safety or utility?

HK: Luckily, we were able to build on the existing MX4 platform, which already has many of these considerations in place. When designing EZ-Lift, we wanted to ensure we weren’t adding anything that would compromise our current safety and utility. We also made sure the new components and features were low-profile so they wouldn’t catch on any cargo or items placed in the bed.  

FB: The market for trucks has clearly grown over the past few years, and we’re seeing lots of first-time owners in the market as well. How do you think EZ-Lift will play a role for these new owners?​

HK: It certainly is a growing market. I think the biggest thing I have noticed over the past few years is that full-size trucks have become the new family vehicles. When you start to see kids and other folks who haven’t owned trucks before becoming the primary users, you start to realize there’s a need for recognizable features that are easy to use. MX4 EZ-Lift caters to those new owners and family members who all interact with the truck on a day-to-day basis.

FB: Looking at the lineup as a whole—the MX4, the MX4 TS, and now the EZ-Lift—how do these updates collectively signal the future of RealTruck’s commitment to American Innovation?

HK: Good question. I think when we look at this new lineup built on an already successful MX4 platform, it shows that we can leverage existing successful innovations and combine them with new innovations emerging today based on user needs. Our commitment to American Innovation has been shaped through these recognitions and our excitement as designers to strive for the next level of form and function in products.

FB: Finally, Harry, what’s one piece of advice you’d give a new customer when they first install and use their new BAKFlip cover?

HK: Leave a little slack for adjustments at the end! I like to leave the two tightening knobs up front a little loose so I can adjust the cover to lie nicely on the bed and bedrail before I tighten everything down. This way, you can shift the cover slightly from front to back and left to right, ensuring that the latches on the sides catch the bed rails equally on both sides of the bed. I also double-check that the bed rails are level and flush with the truck's bed caps. This ensures that all your latches will engage when you first shut the cover after installing.  ​

Huge thanks to Sr. Industrial Designer, Harry Kaloustian, for taking the time to sit down with me to talk truck bed covers. All three members of the MX4 family are currently live on RealTruck—order yours today to experience the industry-leading style, security, and truck bed protection for yourself.