Duratuf TUF 500 User manual

Quality –Made Affordable
ASSEMBLY INSTRUCTIONS
TUF 500
BASE SIZE 1980mm x 1690mm

Tools Required:
Before you start:
Safety:
Select your site:
 Drill
 Drill Bit 3.5mm
 Drill Bit 6mm (for clear roof panel only)
 Riveter
 Hammer
 Nail Punch
 Tape Measure
 Ladder or Saw stool
 String Line
 Masonry Drill and 10mm Masonry Bit (for Bolt Down Kit only)
 Read all instructions carefully.
 Identify all parts and check quantities against checklist.
 If you are making your own floor refer to Raised Base Plate section now.
 Do not attempt to build your shed in high winds.
 Beware of sharp edges.
 Protect your eyes and ears.
 Use electric tools with care. Use a Safety Trip Switch.
 It is easier and quicker if this shed is erected by two people.
 Your shed must be level. Achieve this by either levelling the ground or by using blocks.
 If you shed is to be positioned on wet or damp ground, we recommend that your shed is raised up
off the ground slightly.
2
ASSEMBLY INSTRUCTIONS

3
QTY LENGTH
CHECKED
OUT
CHECKED IN
4 1.890
2 1.890
1 1.890
1 1.890
1 1.890
2 1.890
2 1.890
1
2 1.980 Front & Back
2 1.690 Ends
1 1.980 Back
1 1.980 Front
2 1.690 Ends
4 1.810 Studs
2 1.833 Studs
2 1.600 45 x 45 H1
1 0.106 45 x 45 H1
1 0.823 45 x 45 H1
1 1.890 45 x 45 H1
1
SECURITY
2 Latches
1
1
1
COLOUR: ___________________ INV #:_______________
Folded Roof Sheets
Roof Sheet Or
ROOF SIZE: 2.010 x 1.890
TUF 500 PARTS LIST
1/2 Wall Sheets
TIMBER
Wall Sheets
Corner Wall Sheets
Door
DESCRIPTION
Clear Roof Panel
3/4 Front Wall Sheet (D008)
Back Wall Nog
Front Right Nog
End Wall Nogs
BASE PLATES
- Red 70 x 45 H1
PACKED BY:
DATE: / /
Touch-up Paint & Brush
Hardware Pack
2
1
1.890
2.000
Clear Panel Hardware Pack
BASE SIZE: 1.980 x 1.690
TOP PLATES
1
1.980
Top Plate Flashing
- Green 45 x 45 H4
- Green 45 x 45 H4
- Red 45 x 45 H1
Door Jambs
FLASHINGS
- Red 45 x 45 H1
- Blue 45 x 45 H1
- Yellow 45 x 45 H1
Front Left Nog
1
2.010
Roof Flashing
Assembly Instructions
Clear Panel Brace

Note: For sheds being positioned on a Purpose Built Floor, shorten Studs
by 30mm now (Refer to Floor Section).
Step 1: Select one End Base Plate 1.690m (Green), one End Top Plate
1.690m (Red) and two Studs (Yellow). Lay out on flat surface and nail
together using two 75mm nails per join (fig. 1). Repeat with the other
end frame.
Step 2: Select Back and Front Base Plates 1.980m (Green), Back Top Plate
1.980m (Red) and Front Top Plate (70x45mm). With one End Frame
lying on the ground, nail plates to frame, two 75mm nails per join.
Ensure Green joins to Green and Red joins to Red. See (fig. 2) for
nailing detail on Top Front Plate (70x45mm).
Step 3: Position remaining End Frame on top of plates. While someone sup-
ports frame, nail in place using two 75mm nails per join.
Step 4: Carefully roll frame over onto its base. Nail on Back and End Wall
Nogs .882m above the top of the Bottom plate. If fitting a Duratuf
Floor, fit Floor Joists now. Evenly space joists and nail in place using
three 75mm nails per end. Nail Front wall Studs (Blue) using Front
Wall Nogs to get correct position, Nail remaining Front Wall Nogs in
centrally (this may be easier if the frame is rolled onto its Front wall).
Step 5: Fit front Top Plate Flashing centrally on Front Top Plate using four
30mm Clouts. Position Flashing so that the widest lip is on top.
4
TUF 500 TIMBER FRAME
1
2
3
4
5
fig. 1 fig. 2
YELLOW
BLUE
YELLOW
YELLOW
1.810
YELLOW
BLUE
Top Plate
Flashing

5
TUF 500 WALL CLADDING
fig. 1 fig. 2
To Avoid Corrosion:
Where at all possible try not to trap metal filings between two sheets. Remove all metal filings before riveting.
Carbon in pencils reacts with the Zinc/Aluminium coating on steel. Use ink to mark steel.
Step 1: Door Jambs: Position left hand Door Jamb Flashing at
correct measurement from left (cladding detail) and nail
to Top Plate using a 30mm clout. Do not fit 50mm nails at
this stage. Pre-drill holes to make nailing easier (fig. 1).
Position Door Jamb Flashing and nail at the bottom. Posi-
tion right hand Door Jamb Flashing 903mm from left
hand Door Jamb Flashing (cladding detail) and nail in
place.
903mm180mm
D008
CLADDING DETAIL
Birds Eye View
FRONT VIEW
DOOR JAMB
FLASHING

6
TUF 500 WALL CLADDING
Birds Eye View
D008
= Rivet = 30mm Clout
Step 2: NOTE: It is very important that the Wall
Sheets are positioned exactly as shown in
the cladding detail diagram on the previous
page.
Position Corner Wall Sheets. Check that the
Lip is on the correct side of the sheet. While
holding Corner Wall Sheet flush with the top
of the Top Plate, nail to plate using only one
30mm clout top and bottom.
Step 3: Select Wall Sheet marked D008. Position at
right hand side of doorway. Rivet to Corner
Wall Sheet, one rivet top and bottom. Posi-
tion and rivet in place all remaining Wall
Sheets ensuring they overlap correctly.
While holding Front Wall Sheets up against
Top Plate Flashing, nail to top and bottom
plates using 30mm clouts.
Step 5: Drill a hole through Door Jamb Flashings
and Wall Sheets top and bottom. Nail with
50mm nails (fig. 1).
Nail left hand Door Jamb Flashing to Stud
using three 30mm Clouts at equal spacings
(fig. 1). Beside each 30mm Clout, rivet
Door Jamb Flashing to Rib. Repeat with
right hand Door Jamb Flashing.
Step 4: Nail Wall Sheets to Plates, two 30mm Clouts per pan top and bottom.
Nail Wall Sheets to Wall Nogs, one clout per pan.

TUF 500 ROOF
fig. 1
Step 2: Position Roof so that the front overhang measures
140mm. Rivet roof to wall sheets using one rivet
every second Rib. Repeat at the other end ensuring
overhang measures 140mm.
Step 4: Fit Roof Flashing as shown. When posi-
tioned correctly rivet through Roof Flashing
into Roof Sheet joins.
7
Step 1: Note: Condensation can form on the under side of shed roof. If building paper is required, fit now.
Building paper will need to be supported by netting or roofing twine.
Standard Roof: Position Roof Sheets as shown in fig 1. Make sure sheet joins at the back are flush. Riv-
et sheet joins, one rivet 200mm back from edge front and back. Fit two more rivets evenly spaced in centre of
each join.
Step 1a: Roof with Clear Panel: Refer Next Page
Step 3: Line up ribs on the roof with ribs on the
walls. While someone holds the Front Plate
straight, nail the roof to Top Plate using
one 40mm Weatherseal nail beside each
rib. Repeat at the back.
Step 3a: Roof with Clear Panel: Refer next page
Sealed Rivet
Steel Washer
Clear Roof Panel
Steel
fig. 2

8
TUF 500 CLEAR ROOF PANEL (Optional)
Clear Panel Brace
Roof with Clear Panel:
Handle Clear Panel with care. The Clear Panel will crack if not fitted correctly.
Riveting: Pre-drill 3.3mm hole through Clear Panel and steel.
Nailing: Pre-drill a 6mm hole through Clear Panel. Hammer in nails with caution.
Step 1a: Pre-drill hole in V at both ends of Clear Panel Brace. Position Clear Panel Brace centrally on Top End
Plates and nail in place using a 30mm clout each end (fig. 3).
Position Roof Sheets as shown in fig.1. When fitting Clear Panel ensure it OVERLAPS Roof Sheets. Rivet
sheet joins, one rivet 200mm from edge front and back. When riveting Clear Panel to Roof Sheets use
sealed rivet with steel washer (fig. 2). Fit two more rivets evenly spaced in centre of each join.
Step 2a: Rivet Clear Panel Brace to the Clear Panel, pre-drill holes from underneath then rivet down from on top using
sealed rivets with Steel Washers. For riveting detail see fig. 4.
= Rivet = Rivet with steel washer
Clear Roof Panel
fig. 4
fig. 3

9
TUF 500 DOOR
Step 1: Place shed in final position. Check diagonal
measurements are equal and shed is level
before fitting door.
Step 2:Hold Door in position (approximately 5mm
down from Top Plate Flashing) and fit one rivet to top
hinge. While still holding in position fit one rivet to bottom
hinge.
Step 3:
Close door and check it fits correctly. If not, drill
out rivets and make necessary adjustments. Fit
remaining rivets to all three hinges.
Step 4: Using rivets attach padbolt as shown.
NOTE: If shed has an optional security upgrade, please use Security door instructions on next page.

10
Step 4: Slide the latch on to the handle shaft. Enter shed,
close door and adjust latch so it is snug with the stud
at the side of the door. Tighten up bolt on latch.
Note: Repeat Step 4 for second door handle if double security doors.
FORTRESS SECURITY DOOR (Optional)
Step 1: Place shed in final position. Check diagonal meas-
urements are equal and shed is level before fitting
door.
Step 2: Hold Door in
position (approximately
5mm down from Top
Plate Flashing) and fit
one rivet to top hinge.
While still holding in
position fit one rivet to
bottom hinge.
Step 3: Close door and check it fits correctly. If
not, drill out rivets and make necessary adjust-
ments. Fit remaining rivets to all three hinges.