Tuff Tonneaus 221 Install guide

TONNEAU FITTING INSTRUCTION
Holden Rodeo Space Cab
1997-2003
Part number: 221
Package includes
1 X Tonneau cover
2 x Bar Brackets (300474)
1 x Tonneau Support Bar (300516)
27 x Rivets (300803)
3 x Aluminium Rope Track-484mm long ea.
1 x Lock Bracket
1 x Support Bar Sheath
17 x Rope Buttons (300473)
1 x Fitting Instructions
4 x Dowel
17 x Anti-abrasive disc (300456)

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. 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, 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 905 mm from the inside edge at the front of the tub and place
them. (5mm down from top edge of tub). Drill and rivet, using 4 rivets. Install bar according to
supplied instructions.
6. To fit round body hooks to car measure 160 mm down from inside edge and line up each hook
individually to each bunji (loop) starting with the two either side of the tail gate handle and
working your way around to the front, drill and rivet buttons alternating from side to side.
7. To Fit Anti-Abrasive Discs: Firstly clean the area behind each bunji head with a clean rag and
methylated sprits. Then attach the anti-abrasive discs centrally behind each bunji head.
Placement of aluminium
rope track. Ensure
channel is above the
tub’s top edge.

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.
Placement of bar bracket
905mm

2.2 TONNO LOCK CONTENTS
-2 X 4MM Aluminium rivets
-1 x Tonno Lock bracket
2.3 FITTING TONNO LOCK
1. Attach the 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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Website Link:
http://www.tto.com.au/en-au/warranty.html
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improve for our customers.
Your Tuff Tonneau is now ready for work.