AUSSIE TONNEAU ATB01138 Install guide

TONNEAU COVER FITTING INSTRUCTION
Proton Jumbuck Dual Cab
2003 –2011
Part Number: ATB01138
1. TONNEAU COVER FITTING
NOTE: Read entire instructions prior to start.
1.1 BASIC TOOL REQUIRED
Drill, 4mm Drill Bit, Tape Measure, Rivet Gun, Marking Pencil / Pen, Clear Silicone / Silicone Gun
1.2 CONTENTS
1 x Tonneau Cover 3 x Aluminum Rope Track
2 x Bar Brackets 28 x Rivets
1 x Tonneau Support Bar 14 x Rope Buttons
2 x Alum sealing angles 4 x Pieces of Dowell
1.3 TONNEAU COVER INSTALLATION PROCEDURE
NOTE: Remove swarf and apply Rust Inhibitor to all drilled holes prior to riveting.
1. Place aluminum sealing angle as shown in Figure 1, using two rivets per angle and seal either
side with silicon.
2. Using two pieces of dowel, join the 3 aluminium rope tracks together. Place the other 2 pieces
of dowel in the ends of the now joined rope track. Sit the dowel on top of the sealing angles.
3. Ensure the channel is above the lip’s top edge, so the front bead of the tonneau can slide
through from the side. See Figure 1. Using a 4mm drill bit, drill 6 holes 50mm from the end of
each of the aluminium 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. Mark a position 800mm from the inside edge of the front face of tub towards the rear and
5mm down from the top lip of the tub. Centrally locate the bar bracket over this position and
drill and rivet bracket into place. See Figure 2. Repeat for other side of tub. Fit tonneau
support bar to bar brackets.
6. Slide the front of the tonneau cover through the aluminum rope track section. You will need
someone else to reach across and help pull the tonneau through the rope track. Position the
self-adhesive Velcro strip on the tub as shown in Figure 1 so that it aligns with the Velcro strip
sewn into the tonneau cover. Repeat for other side of tub. Note: Clean this area with soapy
water or methylated spirits prior to adhering the strips to ensure the surface is free from any
dirt, oil and grease.

7. To fit the rope buttons, start with the tailgate and line up vertically each button to each ring
grip then measure 145mm down from the inside edge and drill and rivet each button. See
Figure 3. For the side panels, follow the same procedure as with the tailgate, drill and rivet
buttons alternating from one side to other side of the tub. The front rope button on each side
should be 50mm forward from the ring grip so the ring is on an angle pointing forward.
8. Attach the tonneau cover to all rope buttons.
Figure 1
(Placement of
aluminum rope track.
Ensure channel is
above the lip’s top
edge.)
(Placement of side
sealing angles.)
Figure 2
Placement of Bar
Brackets.
Figure 3
(Placement of Rope
Button)

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-FITT 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.
3.1 BASIC TOOL REQUIRED
Drill, 4mm drill bit
3.2 MULTI SUPPORT BAR CONTENTS
- 1 x hollow bar centrepiece - 2 x grub screws
- 2 x solid bar end piece
3.3 FITTING MULTI SUPPORT 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 FEED BACK
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