Aussie Tonneaus ATR01159 Install guide

TONNEAU COVER FITTING INSTRUCTION
PART NUMBER: ATR01159
TONNEAU COVER TO SUIT FLEXIGLASS TRAY 2350MM X 1805MM
BASIC TOOL REQUIRE
-Rivet gun, Drill, 4.5mm Drill Bit, Measuring Tape, Silicon Sealant, Anti-Corrosive Primer, Marking Pencil
CONTENTS
-1 x Tonneau Cover
-1 x Elastic Rope
-2 x Support Bar
-2 x Aluminium Ropetrack (805mm Long)
-1 x Fitting Instruction
-4 x Bar Brackets
-43 x Rivets
-27 x Rope Buttons
-4 x Dowels
Some items in fitting kit may not be needed. All fitting kits are weighed to ensure accurate quantities.
1. INSTALLATION PROCEDURE
Note: Remove swarf and apply rust inhibitor to all drilled holes prior to riveting.
1. Join 2 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 1bar, 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. Thread the supplied rope in and out of all the eyelets and tie each end off behind the front eyelet on both
sides.
6. 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.
7. To fit the rope buttons. Start with the rear centre eyelet, ensure the Tonneau cover is centred and taught
(this is critical). Vertically line up each rope button individually to the centre between two eyelets (Fig 1).
With a marking pencil make a mark at the height you would like the rope buttons (the continuous rope has a
lot of stretch and can be adjusted to suit different rope button heights).
8. 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 continuous rope as the rope buttons are fitted. At the corners of the tray, fit the button
directly under the last eyelet on the side / back (Fig 2).
9. To fit buttons to the sides of the tray, work from the rear towards the front, alternate from one side of the
vehicle to the other. Line up each rope button (except the rear corners) between two eyelets. Measure down
the same distance used on the rear tailgate of the tray and mark with pencil. Drill and rivet rope button into
position. Secure the Tonneau cover to the vehicle’s sides as the rope buttons are fitted.
10. To tension the rope, start at the front driver’s side of the car. Pull the continuous rope taught around the rope
button and feed the excess rope towards the rear of the tray. Continue to tension the rope around the
buttons around the tray towards the front passenger side. Feed all the excess rope back through the eyelets
until the rope is taught, not tight on all of the rope buttons. At the front passenger side, undo the knot in the
end of the rope, and re-position it just behind the final eyelet on the cover. The excess rope can be cut off
behind this knot, or tucked into the tray for adjustment later.
11. Note: for Tonneaus with a front corner triangle sewn into the front LHS and RHS corners, squeeze the bunji
loop together and make a mark 5mm below its lowest point. This is the height the rope button should be
positioned at. Gauge the most suitable point for the button to be positioned (this can change depending on
the tray make). Drill and rivet the rope button into position and attach bunji loop.

Fig 1
Fig 2

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.