Tuff Tonneaus 10812 Install guide

TONNEAU FITTING INSTRUCTION
Toyota Hilux Extra Cab SR5 A Deck
October 2015 to Current
Part number: 10812
Package includes
 1 X Tonneau cover  4 x Bar Brackets (300474)
 2 x Tonneau Support Bar (300516)  34 x Rivets (300482)
 2 x Support Bar S eat  1 x Lock Bracket
 1 x Fitting Instructions  18 x Rope Buttons (300473)
 1 x Warranty Card  18 x Anti-Abrasive Discs (300456)

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Table of Contents
1. TONNEAU COVER FITTING .............................................................................................................. 3
1.1 BASIC TOOL REQUIRED ................................................................................................................. 3
1.2 TONNEAU COVER INSTALLATION PROCEDURE ............................................................................ 3
2. TONNO LOCK ................................................................................................................................... 5
2.1 BASIC TOOL REQUIRED ................................................................................................................. 5
2.2 TONNO LOCK CONTENTS .............................................................................................................. 5
2.3 FITTING TONNO LOCK ................................................................................................................... 5
3. MULTI-FIT SUPPORT BAR ................................................................................................................ 6
2.1 BASIC TOOL REQUIRED ................................................................................................................. 6
2.2 MULTI-FIT SUPPORT BAR CONTENTS ........................................................................................... 6
2.3 FITTING MULTI-FIT BAR ................................................................................................................ 6

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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, 4.5mm Drill Bit, Rivet Gun, Marking Pencil / Pen
1.2 TONNEAU COVER INSTALLATION PROCEDURE
1.2 TONNEAU COVER INSTALLATION PROCEDURE1.2 TONNEAU COVER INSTALLATION PROCEDURE
1.2 TONNEAU COVER INSTALLATION PROCEDURE
1. To fit bar brackets measure 10mm back from t e rear of t e sports bar and 670mm
from t e tailgate to t e front of t e car (5mm down from top edge of tub). Drill and
rivet using two large rivets for eac Bar Bracket. Install support bar according to
supplied instructions.
2. Fit Round Body Hoo s (Buttons) to Tailgate
Wit a non-permanent marker mark t e positions of t e rear buttons.
- T e first two are 30mm in from eit er side of t e tailgate and 455mm from t e
bottom of t e tailgate.
- T e next two are 242mm in from t e sides of t e tailgate and 455mm from t e
bottom of t e tailgate.
- T e last two are 452mm in from t e sides of t e tailgate and 460mm from t e bottom
of t e tailgate.
- Using a 4.5mm drill bit drill a ole in eac of t ese positions, t en pop rivet a button
into place.
See Figure 1

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3. Fit Round Body Hoo s (Buttons) to the Sides
Firstly attac t e front of t e Tonneau to t e front of t e ute tub placing t e Plastic
Retainer (Fitted on t e Tonneau Cover) on to t e Metal Lip on t e Body, between t e
cabin and t e Ute Body. (Be ind rear windscreen).
Centre t e cover, place it over t e support bar and attac t e rear bunji loops to t e
buttons on t e tailgate.
- On eac side wit a non-permanent marker mark 130mm down from t e inside
edge of t e tub near t e rear bunji.
- Also on eac side, between t e sports bars, mark 135mm down from t e inside
edge of t e tub.
- Wit a straig t edge or string line draw a straig t line between t ese two positions.
Extend t e line to t e front of t e tub.
- Vertically line up each button except the front) to each bunji loop starting from the
rear bunji loop, alternating from side to side working towards the front. Attach each
bunji to the button as it is fitted.
- The front button on each side is placed on the line 140mm from the front of the tub.
30mm 242mm 452mm
455mm
460mm 455mm
Figure 1

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2.
2.2.
2. TONNO LOCK
TONNO LOCKTONNO LOCK
TONNO LOCK
T e Tonno Lock is now a standard feature included wit all
Tuff Tonneaus. T e Tonno Lock is situated at t e front of
t e tonneau cover, so as not to impede t e accessibility of
t e Tuff Tonneau.
Fitting t e lock is simple and only requires a small
attac ment on t e inside edge of t e tub be ind t e cab.
Toget er wit a padlock, it provides you wit an extremely
effective t eft deterrent. T e Tonno Lock is designed to suit
all utes and prevent t ieves stealing your Tuff Tonneau, so you can continue to rely on t e Tuff
Tonneaus’ name to give you w at 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, Torc , and Marking Pencil/Pen.
You will need to buy a small Padlock- make sure t e padlock will go t roug t e ole on t e Tonno lock.
2.2
2.2 2.2
2.2 TONNO LOCK CONTENTS
TONNO LOCK CONTENTSTONNO LOCK CONTENTS
TONNO LOCK 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. Attac t e black lock bracket to t e bracket on t e tonneau wit your padlock, and fit t e tarp.
2. Getting under t e tarp wit a torc , place t e lock bracket against t e body and mark oles wit a
pen.
3. Remove tonneau and drill t e marks wit a 4 mm drill bit, place t e lock bracket in position and
rivet.

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3.
3.3.
3. MULTI
MULTIMULTI
MULTI-
--
-FIT SUPPORT BAR
FIT SUPPORT BARFIT SUPPORT BAR
FIT SUPPORT BAR
T e Tuff Tonneau Multi - Fit Support Bar is designed to fit
almost all Utes on t e Market, from Suburu Brumbys to
Cab C assis aluminium trays.
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 MU
MUMU
MULTI
LTILTI
LTI-
--
-FIT SUPPORT BAR
FIT SUPPORT BARFIT SUPPORT BAR
FIT SUPPORT BAR CONTENTS
CONTENTSCONTENTS
CONTENTS
- 1 x ollow bar centrepiece - 2 x grub screws
- 2 x solid bar end piece - 1 x Tonneau bar s eat
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 eit er end of ollow tube. Adjust bar so it fits between bar bracket
olders wit t e oles facing to t e ground (so t e grub screws don’t rub against t e tonneau),
as s own above and t en wit a w ite pencil make a mark t roug t e small oles of t e
ollow bar onto t e solid ends. T is is w ere you will drill a ole to t e dept of about 1-2mm
(do not go any furt er)
2. Join t e pieces back toget er and screw grub screws t roug t e ollow bar into t e oles t at
you drilled. Ma e sure you do not over tighten the grub screws . T en place t e
tonneau s eat over t e bar to stop t e bar wearing against t e tonneau. Refit t e bar. You
may kink t e bar in t e middle to give it some extra eig t to assist wit water runoff.
Warning if you do not fit the tonneau sheath over the bar, the tonneau cover will quic ly wear
through which is not covered by warranty.
Your Tuff Tonneau is now ready for work.