Tuff Tonneaus 109 User manual

TONNEAU INSTALLATION INSTRUCTION
FORD SUPER CAB, 1985-1998
Part number: 109
Package includes
 1 X Tonneau cover  2 x Bar Brackets (300474)
 1 x Tonneau Support Bar (300516)  24 x Rivets - ST (300482)
 3 x Aluminium Rope Track-476mm long ea.  1 x Lock Bracket
 1 x Support Bar Sheath  12 x Rope Buttons (300473)
 1 x Fitting Instructions  4 x owel
 1 x Warranty Card

2 | P a g e
Table of Contents
1. TONNEAU COVER FITTING .............................................................................................................. 3
1.1 BASIC TOOL REQUIRE ................................................................................................................. 3
1.2 TONNEAU COVER INSTALLATION PROCE URE ............................................................................ 3
1.3 CARING FOR YOUR TONNEAU ...................................................................................................... 4
2. TONNO LOCK ................................................................................................................................... 4
2.1 BASIC TOOL REQUIRE ................................................................................................................. 5
2.2 TONNO LOCK CONTENTS .............................................................................................................. 5
2.3 FITTING TONNO LOCK ................................................................................................................... 5
3. MULTI-FIT SUPPORT BAR ................................................................................................................ 5
2.1 BASIC TOOL REQUIRE ................................................................................................................. 5
2.2 MULTI-FIT SUPPORT BAR CONTENTS ........................................................................................... 5
2.3 FITTING MULTI-FIT BAR ................................................................................................................ 6

3 | P a g e
1.
1.1.
1. TONNEAU COVER FITTING
TONNEAU COVER FITTINGTONNEAU COVER FITTING
TONNEAU COVER FITTING
Some items in the fitting kit may not be needed
All fitting kits are weighed to ensure accurate quantities
1.1 BASIC TOOL REQUIRED
1.1 BASIC TOOL REQUIRED1.1 BASIC TOOL REQUIRED
1.1 BASIC TOOL REQUIRED
rill, 4mm rill Bit, Tape Measure, Rivet Gun, Marking Pencil / Pen, Clear Silicone / Silicone Gun
1.2 TONNEAU COVER INSTALLATION PROCEDURE
1.2 TONNEAU COVER INSTALLATION PROCEDURE1.2 TONNEAU COVER INSTALLATION PROCEDURE
1.2 TONNEAU COVER INSTALLATION PROCEDURE
1. Using two pieces of dowel, join the 3 aluminium rope tracks together. Place the other 2 pieces
of dowel in the ends of the now joined rope track.
2. Rest the aluminium rope track on the side rails as Shown in iagram A, and push forward to the
vertical face of the tub.
3. Using a 4.5 mm drill bit, drill 6 holes 50mm from the end of each of the aluminium rope tracks
into the front of tub.
4. Once all the holes have been drilled, remove the dowelling pieces. Squeeze silicon along the
back of the rope tracks and pop rivet into place.
5. To fit bar brackets measure 910 mm from the inside edge at the front of the tub and place
them as shown in iagram A. (5mm down from top edge of tub) rill and rivet, using 4.5 mm
drill bit and short 4 mm rivets. Insert bar according to supplied instructions.
D agram A
6. rill and rivet hooks as shown in iagram B, using 4.5 mm drill bit and long 4 mm rivet.

4 | P a g e
D agram B
1.3
1.3 1.3
1.3 C
CC
CARING FOR YOUR TONNEAU
ARING FOR YOUR TONNEAUARING FOR YOUR TONNEAU
ARING FOR YOUR TONNEAU
Apply bee's wax or ri-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 dr ve w thout tonneau support bars n place as flapp ng can cause a delam nat ng effect on the
mater al.
"Tonneau is not designed to be used as a load restraint"
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

5 | P a g e
all utes and prevent thieve
s 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, rill, 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 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. 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.
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.
2.1
2.1 2.1
2.1 BASIC TOOL REQUIRED
BASIC TOOL REQUIREDBASIC TOOL REQUIRED
BASIC TOOL REQUIRED
rill, 4mm drill bit
2.2
2.2 2.2
2.2 MULTI
MULTIMULTI
MULTI-
--
-FIT SUPPORT B
FIT SUPPORT BFIT SUPPORT B
FIT SUPPORT BAR
ARAR
AR CONTENTS
CONTENTSCONTENTS
CONTENTS
- 1 x hollow bar centrepiece - 2 x grub screws
- 2 x solid bar end piece - 1 x Tonneau bar sheath

6 | P a g e
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 now ready for work.