Tuff Tonneaus 11303 Install guide

TONNEAU FITTING INSTRUCTION
Isuzu D-Max
Space Cab
September 2020 - Current
Part number: 11303
Package includes
1 X Tonneau cover
4 x Bar Brackets
2 x Tonneau Support Bar
32 x Rivets
2 x Support Bar Sheath
1 x Lock Bracket
1 x Fitting Instructions
18 x Rope Buttons
18 x Anti Abrasive Discs

1. TONNEAU COVER FITTING
NOTE Read entire instructions prior to start.
1.1 BASIC TOOL REQUIRED
Drill, 4mm Drill Bit, Rivet Gun, Marking Pencil / Pen
1.2 TONNEAU COVER INSTALLATION PROCEDURE
1. Fit The Bar Brackets and Support Bars
(a) Measure 600mm and 1200mm from the front inside
edge back along the driver’s side. Place centre of Bar
Bracket at these points with the top of Bar Bracket
10mm down from top edge of tub. Using the Bar
Bracket as a guide, drill into the body.
(b) Apply rust inhibitor and rivet the front and rear holes to
complete attachment of the Bar Bracket. Repeat for the
passenger side of vehicle.
(c) Fit Support Bar according to Section 3 of this Instruction.
2. Fit The Buttons To The Tailgate
(a) Hook the front of the Cover onto the front edge of the Ute Tub. Centre the cover and evenly spread
across the tub.
(b) To fit buttons, vertically line up each button to each bunji loop, Starting from the Centre Bunjis.
The height of the 6 Tailgate Buttons are 460mm from the bottom edge of the tailgate.
(c) Drill holes then apply rust inhibitor and rivet buttons into place, attaching the bunji after each
button is placed. See Figure 2
Figure 2
Figure 1
460mm

3. Fit The Buttons To Tub Sides
(a) Measure down 170mm from the inside edge of the tub,
in line with the Front Bunji on the Cover, and mark. This
is the position of the front button. See Figure 3
(b) Measure down 140mm from the inside edge of the tub,
in line with the Rear-Side Bunji and mark. See Figure 4
(c) Using a straight edge or string line, draw a line between
front mark & rear mark as shown in Figure 5
(d) Repeat those steps for passenger side
Figure 3
170
Figure 4
Figure 5

(e) Work from the rearmost bunjis towards the front,
alternating from side to side.
(f) Line up the rearmost bunji loop (#1) on the driver’s side
of the vehicle and make a mark on the line drawn in step
4 (c).
(g) Drill hole and rivet button into place as shown in Figure
12.
(h) Repeat step 3 (e) to (g) for the rear most bunji loop (#2)
on the passenger side of the vehicle.
(i) Fit remaining 10 bunjis following the sequence as in
Figures 6 & 7.
Note: Ensure you work from side to side to maintain tension across the tonneau cover
Figure 6
Figure 7

2. 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 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 TONNO LOCK CONTENTS
-2 X 4MM Aluminium rivets
-1 x Tonno Lock bracket
2.3 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. 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.
3.1 BASIC TOOL REQUIRED
Drill, 4mm drill bit

3.2 MULTI-FIT SUPPORT BAR CONTENTS
-1 x hollow bar centrepiece - 2 x grub screws
-2 x solid bar end piece - 1 x Tonneau bar sheath
3.3 FITTING MULTI-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 tighten 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.
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.
4. WARRANTY AND FEEDBACK
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