Tuff Tonneaus 10522 Install guide

TONNEAU FITTING INSTRUCTION
Isuzu D-Max Dual Cab With Head Board
Jul 2012 to Current
Part number: 10522
Package includes
 1 X Tonneau cover  2 x Bar Brackets (300474)
 1 x Tonneau Support Bar (300516)  28 x Rivets (300482)
 1 x Rope Track 1253mm (With Shim)  1 x Lock Bracket
 1 x Support Bar Sheath  16 x Rope Buttons (300473)
 1 x Fitting Instructions  2 x Dowel
 1 x Warranty Card  4 x M8 Bolt (S 0050)
 1 x LH Front cnr seal plate A300118
 1 x RH Front cnr seal plate A300119

2 | P a g e
Table of Contents
1. TONNEAU COVER FITTING .............................................................................................................. 3
1.1 BASIC TOOL REQUIRED ................................................................................................................. 3
1.2 TONNEAU COVER INSTALLATION PROCEDURE ............................................................................ 3
2. TONNO LOCK ................................................................................................................................... 6
2.1 BASIC TOOL REQUIRED ................................................................................................................. 6
2.2 TONNO LOCK CONTENTS .............................................................................................................. 6
2.3 FITTING TONNO LOCK ................................................................................................................... 6
3. MULTI FIT SUPPORT BAR ................................................................................................................ 7
2.1 BASIC TOOL REQUIRED ................................................................................................................. 7
2.2 MULTI FIT SUPPORT BAR CONTENTS ........................................................................................... 7
2.3 FITTING MULTI FIT BAR ................................................................................................................ 7

3 | P a g e
1.
1.1.
1. TONNEAU COVER FITTING
TONNEAU COVER FITTINGTONNEAU COVER FITTING
TONNEAU COVER FITTING
NOTE
Read entire instructions prior to start.
1.1 BASIC TOOL REQUIRED
1.1 BASIC TOOL REQUIRED1.1 BASIC TOOL REQUIRED
1.1 BASIC TOOL REQUIRED
Drill, 4mm Drill Bit, Rivet Gun, Marking Pencil / Pen
1.2 TONNEAU COVER
1.2 TONNEAU COVER 1.2 TONNEAU COVER
1.2 TONNEAU COVER INSTALLATION PROCEDURE
INSTALLATION PROCEDUREINSTALLATION PROCEDURE
INSTALLATION PROCEDURE
NOTE Remove swarf and a ly the rovided Rust Inhibitor to all drilled holes rior to
riveting. Read entire instructions rior to start.
1. To attach seal plates, remove the top bolt on each side of the inside edge that secures the head
board. Place the seal plate against the inside of the head board and relace bolt. DO NOT
TIGHTEN YET.
2. Align the seal plate so the top surface sits level with the top front edge of the tub. With 4mm
drill bit, drill a hole in the front face of the tub through the existing hole in the seal plate on
each side. DO NOT RIVET YET.
3. Remove seal plate and clean swarf from the tub and seal plate. Apply a bead of silicone to the
back of the seal plate. Reposition seal plate against the front face of the tub. Insert 4mm rivet
and rivet into place. Tighten bolts in head board.
4. Place one piece of dowel in each end of the rope track. Rest rope track and dowel on the top
edge of the seal plates. Ensure the flat side of the rope track is the surface positioned against
the tub face. See F gure 1.
5. Drill 4mm hole through each of the holes in the rope track into the front edge of the tub. Place
a 4mm rivet in each hole as it is drilled. DO NOT RIVET YET. Once all holes have been drilled,
remove the rivets, rope track and dowels.
6. Apply a bead of clear silicone along the centre of the front edge of the rope track (the side that
contacts the tub).
7. Rivet the aluminium rope track into position.
8. With the pencil mark the inside edge on each side of the tub at 740mm from the inside front
face of tub towards the rear on each side. Centrally locate the bar bracket over this position
and align the top of the bar bracket 10mm down from the top edge of the tub and drill and
rivet bracket into place. See F gure 2. Repeat for other side of tub. Fit tonneau support bar to
bar brackets.

4 | P a g e
9.
Slide the front of the tonneau cover through the alumin
i
um rope track section.
10. Ensure tonneau s centred. To fit the rope buttons to the tub, start with the ta lgate, vertically
line up each button to each bunji loop starting from the centre bunji loops. The height for the
buttons on the tailgate is 410mm UP from the bottom edge of the tailgate. Work from the
centre out, alternating from side to side. Attach each bunji to the button as it is fitted.
11. To fit the rope buttons to the sides, vertically line up each button to each bunji loop starting
from the rear bunji loop, alternating from side to side working towards the front. The height for
the side rope buttons are all measured down from the TOP INSIDE EDGE of the tub. For the
rear button measure 160mm, 165mm for the second button from the rear, and 170mm for the
next two buttons. For the button closest to the front of the tub measure 175mm down and
25mm back from the front edge of the tub. Attach each bunji to the button as it is fitted.
NOTE: All measurements are to be taken from the TOP INSIDE EDGE of the tub.
12. To fit Velcro to the tub release the front bunji on each side. Fold the cover back to reveal the
hook side Velcro (attached to the loop side on the cover). Peal the backing from the velcro and
fold back onto the top edge of the tub. ALLOW 30 MINUTES FOR THE VELCRO TO ADHERE.

5 | P a g e
F gure 2: Placement of
bar bracket
F gure 1: Placement of
aluminium rope track.
Ensure channel is above
the tub’s top edge.
10mm down
from top edge
of tub
740mm

6 | P a g e
2.
2.2.
2. TONNO LOCK
TONNO LOCKTONNO LOCK
TONNO LOCK
The Tonno Lock is now a standard feature included with all
Tuff Tonneaus. The Tonno Lock is situated at the front of
the tonneau cover, so as not to impede the accessibility of
the Tuff Tonneau.
Fitting the lock is simple and only requires a small
attachment on the inside edge of the tub behind the cab.
Together with a padlock, it provides you with an extremely
effective theft deterrent. The Tonno Lock is designed to suit
all utes and prevent thieves stealing your Tuff Tonneau, so you can continue to rely on the Tuff
Tonneaus’ name to give you what you want in a tonneau cover.
2.1
2.1 2.1
2.1 BASIC TOOL REQUIRED
BASIC TOOL REQUIREDBASIC TOOL REQUIRED
BASIC TOOL REQUIRED
Rivet gun, Drill, Torch, and Marking Pencil/Pen.
You will need to buy a small Padlock make sure the padlock will go through the hole on the Tonno lock.
2.2
2.2 2.2
2.2 TONNO L
TONNO LTONNO L
TONNO LOCK CONTENTS
OCK CONTENTSOCK CONTENTS
OCK CONTENTS
2 X 4MM Aluminium rivets
1 x Tonno Lock bracket
2.3
2.3 2.3
2.3 FITTING TONNO LOCK
FITTING TONNO LOCKFITTING TONNO LOCK
FITTING TONNO LOCK
1. Attach the black lock bracket to the bracket on the tonneau with your padlock, and fit the tarp.
2. Getting under the tarp with a torch, place the lock bracket against the body and mark holes with a
pen.
3. Remove tonneau and drill the marks with a 4 mm drill bit, place the lock bracket in position and
rivet.

7 | P a g e
3.
3.3.
3. MULTI
MULTIMULTI
MULTI-
--
-FIT SUPPORT BAR
FIT SUPPORT BARFIT SUPPORT BAR
FIT SUPPORT BAR
The Tuff Tonneau Multi Fit Support Bar is designed to fit
almost all Utes on the Market, from Suburu Brumbys to
Cab Chassis aluminium trays.
Part No: BARADJ
2.1
2.1 2.1
2.1 BASIC TOOL REQUIRED
BASIC TOOL REQUIREDBASIC TOOL REQUIRED
BASIC TOOL REQUIRED
Drill, 4mm drill bit
2.2
2.2 2.2
2.2 MULTI
MULTIMULTI
MULTI-
--
-FIT SUPPORT BAR
FIT SUPPORT BARFIT SUPPORT BAR
FIT SUPPORT BAR CONTENTS
CONTENTSCONTENTS
CONTENTS
1 x hollow bar centrepiece 2 x grub screws
2 x solid bar end piece 1 x Tonneau bar sheath
2.3
2.3 2.3
2.3 FITTING
FITTING FITTING
FITTING MULTI
MULTIMULTI
MULTI-
--
-FIT BAR
FIT BARFIT BAR
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 t ghten the grub screws . Then place the
tonneau sheath over the bar to stop the bar wearing against the tonneau. Refit the bar. You
may kink the bar in the middle to give it some extra height to assist with water runoff.
Warn ng f you do not f t the tonneau sheath over the bar, the tonneau cover w ll qu ckly wear
through wh ch s not covered by warranty.
Your Tuff Tonneau is no ready for ork.