AUSSIE TONNEAU ATB01120 User manual

TONNEAU COVER INSTALLATION INSTRUCTIONS
TOYOTA HILUX “J” DECK DUAL CAB
APR 2005 –SEP 2015
PART NO: ATB01120
BASIC TOOLS REQUIRED
-Rivet gun, Drill, 4.0mm Drill bit, Measuring tape, Silicon sealant, Anti-corrosive primer.
CONTENTS
1 X Tonneau cover 3 X Aluminum rope track (503mm each)
2 X Bar Brackets 1 X Tonneau support bar
18 X Buttons 29 X Large rivet
4 X Pieces of dowel
Some items in the fitting kit may not be needed. All fitting kits are weighed to ensure accurate quantities.
1. INSTALLATION PROCEDURE
Note: To prevent corrosion apply an anti-corrosive primer to all holes drilled.
1. Using two pieces of dowel, join the 3 aluminum rope tracks together. Place the other 2 pieces of dowel in
the ends of the now joined rope track.
2. Rest the aluminum rope track on the side rails as Shown in Diagram A, and push forward to the vertical
face of the tub.
3. Using a 4.5 mm drill bit, drill 6 holes 50mm from the end of each of the aluminum rope tracks into the
front of tub.
4. Once all the holes have been drilled, remove the dowelling pieces. Squeeze silicon along the back of the
rope tracks and pop rivet into place.
5. To fit bar brackets measure 760mm back from the inside front edge at the top of the tub and place them
as shown in diagram A. (5mm down from top edge of tub). Drill and rivet using two large rivets for each
Bar Bracket. Install support bar according to supplied instructions.
6. To fit round body hooks measure 170mm down from the inside edge and line up each hook individually to
each bunji loop starting with the two either side of the tailgate handle and working your way around to
the front, drill and rivet buttons alternating from side to side.

Diagram A
Diagram B
2. CARING FOR YOUR TONNEAU
Apply bee's wax or Dri-lube to stitching a few times a year, as this will maintain the tonneau's waterproofing
ability and prevent the stitching from degrading. Use a mild detergent and soft scrubbing brush to clean tonneau.
Never drive without tonneau support bars in place as flapping can cause a delaminating effect on the material.
"Tonneau is not designed to be used as a load restraint"

3. MULTI-FIT SUPPORT BAR
The Aussie Tonneau Multi - Fit Support Bar is designed to fit almost all Utes on the Market, from Suburu Brumbys
to Cab Chassis aluminium trays.
2.1 BASIC TOOL REQUIRED
- Drill, 4mm drill bit
3.2 MULTI-FIT SUPPORT BAR CONTENTS
-1 x hollow bar centrepiece - 2 x grub screws
-2 x solid bar end piece
2.3 FITTING MULTI-FIT BAR
1. Insert solid bar pieces into either end of hollow tube. Adjust bar so it fits between bar bracket holders
with the holes facing to the ground (so the grub screws don’t rub against the tonneau), as shown above
and then with a white pencil make a mark through the small holes of the hollow bar onto the solid ends.
This is where you will drill a hole to the depth of about 1-2mm (do not go any further)
2. Join the pieces back together and screw grub screws through the hollow bar into the holes that you
drilled. Make sure you do not over tighten the grub screws. Refit the bar. You may kink the bar in the
middle to give it some extra height to assist with water runoff.
4. WARRANTY AND FEEDBACK
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Thank you for purchasing an Aussie Tonneaus Product.