Tuff Tonneaus 144 Install guide

TONNEAU FITTING INSTRUCTION
Ford PX Ranger Single Cab (with head board)
Nov 2011-May 2013
Part number: 144
Package includes
 1 X Tonneau cover  4 x Bar Brackets (300474)
 2 x Tonneau Support Bar (300516)  40 x Rivets (300482)
 3 x luminium Rope Track-403mm long ea.  1 x Lock Bracket
 1 x Support Bar Sheath  24 x Rope Buttons (300473)
 1 x Fitting Instructions  4 x Dowel
 1 x Warranty Card  2 x 100mm angle pieces (S-0047)

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Table of Contents
1. TONNE U COVER FITTING .............................................................................................................. 3
1.1 B SIC TOOL REQUIRED ................................................................................................................. 3
1.2 TONNE U COVER INST LL TION PROCEDURE ............................................................................ 3
2. TONNO LOCK ................................................................................................................................... 5
2.1 B SIC TOOL REQUIRED ................................................................................................................. 5
2.2 TONNO LOCK CONTENTS .............................................................................................................. 5
2.3 FITTING TONNO LOCK ................................................................................................................... 5
3. MULTI-FIT SUPPORT B R ................................................................................................................ 6
2.1 B SIC TOOL REQUIRED ................................................................................................................. 6
2.2 MULTI-FIT SUPPORT B R CONTENTS ........................................................................................... 6
2.3 FITTING MULTI-FIT B R ................................................................................................................ 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, 4mm Drill Bit, Rivet Gun, Marking Pencil / 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 Fit the pieces of angle to the outside edge of the head board making sure the top
flat edge of the angle is at the same height as the top lip of the head board Drill two
4mm holes in each piece of angle, silicone behind is, then rivet into place
2 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
3 Rest the aluminium rope track on the pieces of angle already fixed in place, and
push forward to the vertical face of the head board See Figure 1
4 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
5 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
6 To fit bar brackets measure 750mm and 1500mm back from the inside front edge at
the top of the tub and place them as shown in Figure 2 (5mm down from top edge
of tub) Drill and rivet using two large rivets for each Bar Bracket Install support bar
according to supplied instructions
7 To fit round body hooks to the tail gate, measure 465mm up from the bottom edge
of the tail gate and line up each hook individually to each bunji loop starting with the
two either side of the tailgate handle and working your way to the outside, drill and
rivet buttons alternating from side to side
8 To fit round body hooks to the sides of the tub measure 155mm down from the
inside edge and line up each hook individually to each bunji loop Start with the two
rear bunjis and work your way around to the front, drill and rivet buttons alternating
from side to side

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Figure 2: Placement of
bar bracket
750mm &
1500mm
Figure 1: Placement of
aluminium rope track.
Ensure channel is above
the tub’s top edge.

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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
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
2.1 2.1
2.1 BASIC TOOL REQUIRED
BASIC TOOL REQUIREDBASIC TOOL REQUIRED
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
2.2 2.2
2.2 TONNO LOCK CONTENTS
TONNO LOCK CONTENTSTONNO LOCK CONTENTS
TONNO LOCK CONTENTS
- 2 X 4MM luminium 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. ttach 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.

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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 Multi - Fit Support Bar is designed to fit
almost all Utes on the Market, from Suburu Brumbys to
Cab Chassis aluminium trays.
Part No: B R DJ
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 hollow bar centrepiece - 2 x grub screws
- 2 x solid 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 solid bar pieces into either end of hollow tube. djust 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 o 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 o not fit the tonneau sheath over the bar, the tonneau cover will quickly wear
through which is not covere by warranty.
Your Tuff Tonneau is now ready for work.