AUSSIE TONNEAU ATB01152 Install guide

TONNEAU COVER FITTING INSTRUCTION
PART NUMBER: ATB01152
TONNEAU COVER TO SUIT TRIPLE M 2400 X 1712MM
BASIC TOOL REQUIRE
-Rivet gun, Drill, 4.5mm Drill Bit, Measuring Tape, Silicon Sealant, Anti-Corrosive Primer,
Marking Pencil
CONTENTS
1 x Tonneau Cover 4 x Bar Brackets
2 x Tonneau Support Bar 43 x Rivets
2 x Aluminium Ropetrack 4 x Dowels
1 x Fitting Instruction 27 x Rope Buttons
1. INSTALLATION PROCEDURE
Note: Remove swarf and apply rust inhibitor to all drilled holes prior to riveting.
1. Join 2 or 3 pieces of rope track with dowel supplied. Place 1 piece of dowel in each end of the
joined rope track.
2. Place the rope track with dowel placed in the ends of the rope track on the top edge of the
drop sides and push up against the front vertical edge of the tray. This is to ensure the rope
track is at the correct height and the front bead of the Tonneau cover can slide through from
the side. Refer Diagram A.
3. Using a 4.5mm drill bit, drill six holes through the aluminium rope track and into the front face
of the tray; one at 50mm from either edge, with the others evenly spaced between the outer
two positions. Remove rope track and run a bead of silicone along the flat edge of the rope
track, then rivet the aluminum rope track into position.
4. To install your support bar. Measure the inside length of the tray. If you have been supplied 1
bar, halve this measurement and that is the support bar position. If you have been supplied 2
bars divide the measurement by 3 and these are the support bar positions. Centrally locate
each bar bracket over these positions 5mm down from the top edge, drill and rivet the bar
brackets into place. Repeat for the remaining bar brackets on both sides of the tray. Fit the
Tonneau support bar/s to the bar brackets. (See Multi-Fit Bar Instruction overleaf)
5. Slide the front of the Tonneau cover through the aluminum rope track section. Neatly spread
the Tonneau cover over the support bar/s, so it is centered and fully covers the tray.

6. To fit the rope buttons. Start with the rear centre bunjis (loops), ensure the Tonneau cover is
centred and taught (this is critical). Vertically line up each rope button individually to each bunji,
squeeze the centre bunji loop together, with a marking pencil make a mark at the lower end of
the bunji. This mark is the place to drill a hole and secure the first button with a pop rivet.
Measure the distance between the top of the tailgate to the button and use this measurement
to repeat the process for the remaining buttons on the tailgate, alternating from one side to the
other. Secure the Tonneau cover to the tailgate using the bunjis as the rope buttons are fitted.
See Diagram B.
7. To fit the rope buttons to the sides of the vehicle. Vertically line up each rope button
individually to each bunji (loop) starting with both rear corners. Pull the left hand side bunji
down until the bunji and the Tonneau cover are centered and taught (this Is critical). Using the
marking pencil, mark the positions of the rope buttons. Now measure each side from the top
of the drop side to the new mark, these should be the same distance (if they are not, ensure
the cover is centered in the width and try again) Drill and rivet the 2 rope buttons to the rear
sides of the vehicle. Repeat this procedure for the remaining rope buttons. Alternate from
one side of the vehicle to the other. Secure the Tonneau cover to the vehicle’s sides as the
rope buttons are fitted.
8. Note: if the side bunji nearest the front are the same length as the rest of the bunjis, the
buttons should be fitted directly in line with the front bunji. If the side bunji nearest the front
on each side of the Tonneau are longer than the side bunjis these buttons must be secured
towards the front of the tray. For example, repeat the measurement down from top of the
drop side and make a mark. From this mark, measure 65mm towards the front of the tray and
mark this point. Drill and rivet the rope button and secure the Tonneau. Repeat this procedure
for the other side of the tray.
9. Note: for Tonneaus with a front corner triangle sewn into the front LHS and RHS corners,
repeat the above process to determine the height of the bunji. Place bunji where appropriate
for specific vehicle.

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.
3.1 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
3.3 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.