Tuff Tonneaus 10634 Install guide

TONNEAU FITTING INSTRUCTION
JMC Vigus Dual Cab Ute
Bunji Loop Soft Tonneau Cover
Part number: 10634

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Supplied Parts.
Check the contents of the kit prior to fitment.
Ensure that your new tonneau fitting kit is complete. Please read the fitting instructions carefully and
completely before attempting to fit your tonneau.
4 mm Rivets (300803) x
22
Alcohol Wipes x
3
Bar Brackets (300474) x 2
Rust Preventative x 1
Anti-Abrasive Discs x
13
Fitting Instructions x
1
Tonneau Cover x
1 (1405mm)
Support Bar x 1
Support Bar Sheath x
1
Kit
Complete
FORD
RANGE
R
FITTIN
G
Instructions
Buttons (300473) x 13
Rope Track x 1
Front
Aluminium
Angle x 3

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1. TONNEAU COVER FITTING
NOTE: Read entire instructions prior to start.
1.1 BASIC TOOL REQUIRED
Drill, 4mm Drill Bit, Rivet Gun, Tape Measure, Marking Pencil / Pen
1.2 TONNEAU COVER INSTALLATION PROCEDURE
1. Fit The Front Rail
(a) Take the piece of aluminium angle that is 1500mm long. On the
face with straight edges measure and drill, using a 4mm drill bit,
5 holes as shown in figure 1.
(b) The centre and 2 outside holes are 35 mm up from the edge. The
2 lower holes are 10mm up from the edge. See Figure 1.
(c) Place against the front inside edge of the tub with the angle
facing inside the tub.
(d) With the aluminium level with the top of the tub drill through the
holes into the tub, starting from the centre hole. Rivet into place
as you drill the holes.
(e) Take the two side aluminium angles that are 475mm long. With a
4mm drill bit measure and drill 2 holes on each part, 90mm and
415mm on the face with straight edges from the front. See
Figure 2
(f) Drill and rivet the two side pieces of angle into place on both sides
of the piece already attached in step 1. See Figure 3
(g) Silicon where the aluminium angle meets the inside edge of the
tub and where the two side angles join the larger piece.
2. Fit The Ropetrack
(a) Line up the rope track with the edge front angle with the ‘C’
channel facing forward (as shown in Figure 4). Centralise the
rope track.
(b) With a 4mm drill bit, Drill 5 holes evenly spaced in the rope track
and into the aluminium angle.
(c) Place a 4mm rivet in each hole as it is drilled, but do not rivet.
Figure 1
Figure 2
Figure 3
Figure 4

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(d) Once all holes have been drilled, remove the rivets and rope
track and clean any swarf away.
(e) Apply a bead of silicone to the flat face of the rope track and
place the rope track back in position. See Figure 5
(f) Rivet the rope track into place
3. Fit The Bar Brackets
(a) From the aluminium angle on the side of the tub measure back
290mm. Place centre of Bar Bracket at this point with the top of
Bar Bracket even with the top edge of tub. Using the Bar Bracket
as a guide, drill into the body. See Figure 6
(b) Apply rust inhibitor and rivet the front and rear holes to complete
attachment of the Bar Bracket.
(c) Repeat for the passenger side of vehicle.
(d) Follow Section 2 to fit the support bar.
4. Fit The Buttons To Tailgate
(a) To attach Bunjis, firstly slide the front of the cover into the Rope Track channel and drape the cover over
support bar and across the tub.
(b) Using a straight edge or string line, draw a line 590mm from the bottom edge of the tailgate, then measure
and mark the centre of the line.
(c) From the centre measure and mark positions 300mm and 600mm to the left and to the right.
Figure 5
Figure 6
Figure 7

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5. Fit The Buttons To The Sides
(a) Place a straight edge under the two external tie downs and draw
a line. This will be the height of the buttons. See Figure 8
(b) Starting from the rear driver’s side bunji, mark directly below the
bunji on the straight line.
(c) Drill and pop rivet a button into this position and attach the
bunji. Repeat for the opposite corner.
(d) Mark directly below the second bunji from the back on the driver’s side.
(e) Drill and pop rivet a button into this position and attach the bunji. Repeat for the opposite side.
(f) Mark directly below the third bunji from the back on the driver’s side.
(g) Drill and pop rivet a button into this position and attach the bunji. Repeat for the opposite side.
(h) For the closest bunji to the front attach the button at the same height but measure back from the front of the
tub 515mm, so the button is to the front of the bunji. Attach the 2 front bunjis to the buttons.
(i) To Fit Anti-Abrasive Discs: Firstly clean the area behind each bunji head with a clean rag and methylated
sprits. Then attach the anti-abrasive discs centrally behind each bunji head.
This complete installation.
2. MULTI-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.
2.1 BASIC TOOL REQUIRED
Drill, 4mm drill bit
2.2 MULTI-FIT SUPPORT BAR CONTENTS
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. Then place the tonneau sheath over the
Figure 8

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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.
Warning if you do not fit the tonneau sheath over the bar, the tonneau cover will quickly wear through which is
not covered by warranty.
3. WARRANTY AND FEEDBACK
Please register your warranty details online at:
QR Code:
Website Link:
http://www.tto.com.au/en-au/warranty.html
Please complete our 2 minute feedback section as we strive to constantly improve for our
customers.
Your Tuff Tonneau is now ready for work.