Tuff Tonneaus 141 Install guide

TONNEAU FITTING INSTRUCTION
Ford F250/350 EXTRA/SINGLE CAB TONNEAU
2001-CURRENT
Part number: 141
Package includes
 1 X Tonneau cover  4 x Bar Brackets (300474)
 2 x Tonneau Support Bar (300517)  38 x Rivets (300482)
 3 x A uminium Rope Track-546mm ong ea.  1 x Lock Bracket
 1 x Support Bar Sheath  24 x Rope Buttons (300473)
 1 x Fitting Instructions  4 x Dowe
 1 x Warranty Card

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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
Dri , 4mm Dri Bit, Rivet Gun, Marking Penci / Pen
1.2 TONNEAU COVER INSTALLATION
1.2 TONNEAU COVER INSTALLATION 1.2 TONNEAU COVER INSTALLATION
1.2 TONNEAU COVER INSTALLATION PROCEDURE
PROCEDUREPROCEDURE
PROCEDURE
1. Using wo pieces of dowel, join he 3 aluminium rope racks oge her. Place he o her 2
pieces of dowel in he ends of he now joined rope rack.
2. Res he aluminium rope rack on he side rails as Shown in Diagram A, and push forward
o he ver ical face of he ub.
3. Using a 4.5 mm drill bi , drill 6 holes 50mm from he end of each of he aluminium rope
racks in o he fron of ub.
4. Once all he holes have been drilled, remove he dowelling pieces. Squeeze silicon along
he back of he rope racks and pop rive in o place.
5. To fi he bar bracke s measure he dis ance from he inside fron edge of he ub o he
inside edge of he ailga e. Divide he measuremen by 3 and place he bar bracke s an
equal dis ance apar as shown in diagram A. (5mm down from op edge of ub). Drill and
rive he bar bracke s using wo rive s for each bar bracke . Ins all each suppor bar
according o he supplied ins ruc ions.
6. To fi he round body hooks o he car, pull he onneau igh and squeeze he bunji loop
oge her. Draw a mark a he bo om of bunji, his is he heigh o drill he holes for he
round body hooks ( he sides may be a differen heigh o he back). Line up each hook
individually o each bunji loop s ar ing wi h he wo ei her side of he ailga e handle and
working your way around o he fron , drill and rive body hooks al erna ing from side o
side. Refer o Diagram B.

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2.
2.2.
2. TONNO LOCK
TONNO LOCKTONNO LOCK
TONNO LOCK
The Tonno Lock is now a standard feature inc uded with a
Tuff Tonneaus. The Tonno Lock is situated at the front of
the tonneau cover, so as not to impede the accessibi ity of
the Tuff Tonneau.
Fitting the ock is simp e and on y requires a sma
attachment on the inside edge of the tub behind the cab.
Together with a pad ock, it provides you with an extreme y
effective theft deterrent. The Tonno Lock is designed to suit
a utes and prevent thieves stea ing your Tuff Tonneau, so you can continue to re y 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 REQ
BASIC TOOL REQBASIC TOOL REQ
BASIC TOOL REQUIRED
UIREDUIRED
UIRED
Rivet gun, Dri , Torch, and Marking Penci /Pen.
You wi need to buy a sma Pad ock- make sure the pad ock wi go through the ho e on the Tonno ock.
2.2
2.2 2.2
2.2 TONNO LOCK CONTENTS
TONNO LOCK CONTENTSTONNO LOCK CONTENTS
TONNO LOCK CONTENTS
- 2 X 4MM A uminium rivets
- 1 x Tonno Lock bracket
2.3
2.3 2.3
2.3 FITTING TONNO
FITTING TONNO FITTING TONNO
FITTING TONNO LOCK
LOCKLOCK
LOCK
1. Attach the b ack ock bracket to the bracket on the tonneau with your pad ock, and fit the tarp.
2. Getting under the tarp with a torch, p ace the ock bracket against the body and mark ho es with a
pen.
3. Remove tonneau and dri the marks with a 4 mm dri bit, p ace the ock 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
The Tuff Tonneau Mu ti - Fit Support Bar is designed to fit
a most a Utes on the Market, from Suburu Brumbys to
Cab Chassis a uminium trays.
Part No: BARADJ
2.1
2.1 2.1
2.1 BASIC TOOL REQUIRED
BASIC TOOL REQUIREDBASIC TOOL REQUIRED
BASIC TOOL REQUIRED
Dri , 4mm dri 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 ho ow bar centrepiece - 2 x grub screws
- 2 x so id 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 so id bar pieces into either end of ho ow tube. Adjust bar so it fits between bar bracket
ho ders with the ho es facing to the ground (so the grub screws don’t rub against the tonneau),
as shown above and then with a white penci make a mark through the sma ho es of the
ho ow bar onto the so id ends. This is where you wi dri a ho e to the depth of about 1-2mm
(do not go any further)
2. Join the pieces back together and screw grub screws through the ho ow bar into the ho es that
you dri ed. Make sure you do not over tig ten t e grub screws . Then p ace the
tonneau sheath over the bar to stop the bar wearing against the tonneau. Refit the bar. You
may kink the bar in the midd e to give it some extra height to assist with water runoff.
Warning if you do not fit t e tonneau s eat over t e bar, t e tonneau cover will quickly wear
t roug w ic is not covered by warranty.
Your Tuff Tonneau is now ready for work.