Tuff Tonneaus 322NSB User manual

TONNEAU INSTALLATION INSTRUCTION
D22 Navara 4WD ST-R Dual Cab,
Oct 2001 – 2005 Without Sports Bars
Part number: 322NSB
Package includes
 1 X Tonneau cover  2 x Bar Brackets (300474)
 1 x Tonneau Support Bar (300516)  26 x Rivets – ST (300482)
 3 x Aluminium Rope Track-461mm long ea.  1 x Lock Bracket
 1 x Support Bar Sheath  14 x Rope Buttons (300473)
 1 x Fitting Instructions  4 x owel
 1 x Warranty Card

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Table of Contents
1. TONNEAU COVER FITTING .............................................................................................................. 3
1.1 BASIC TOOL REQUIRE ................................................................................................................. 3
1.2 TONNEAU COVER INSTALLATION PROCE URE ............................................................................ 3
2. TONNO LOCK ................................................................................................................................... 5
2.1 BASIC TOOL REQUIRE ................................................................................................................. 5
2.2 TONNO LOCK CONTENTS .............................................................................................................. 5
2.3 FITTING TONNO LOCK ................................................................................................................... 5
3. MULTI-FIT SUPPORT BAR ................................................................................................................ 6
2.1 BASIC TOOL REQUIRE ................................................................................................................. 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
rill, 4mm rill Bit, Rivet Gun, Marking Pencil / Pen
1.2 TONNEAU COVER INSTALLATION PROCEDURE
1.2 TONNEAU COVER INSTALLATION PROCEDURE1.2 TONNEAU COVER INSTALLATION PROCEDURE
1.2 TONNEAU COVER INSTALLATION PROCEDURE
1. sing 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, and push forward. Figure 1 to the
vertical face of the tub.
3. sing a 4 mm drill bit, drill 6 holes 50mm from the end of each of the aluminium rope
tracks into the front of tub.
4. sing a 4 mm drill bit, drill 6 holes 50mm from the end of each of the aluminium rope
tracks into the front of tub.
5. Slide the front of the tonneau cover through the aluminium rope track section.
6. To fit the bar brackets, measure 700mm back from the inside front edge at the top of
the tub and place them as shown in Figure 2. (10mm down from top edge of tub) Drill
and rivet using two large rivets for each Bar Bracket. Install the support bar according to
the supplied instructions.
7. Neatly lay tonneau out over support bar and tub in the installed position. Fasten all
collars around sports bar legs with the press studs.
8. To fit the rope buttons to tub, use the panel crease in both the tailgate and side panels
as a reference line, See Figure 3. Starting with the tailgate, line up vertically each
button to each ring grip and drill and rivet each button to the crease, so that the top
edge of the button is in line with the top edge of the crease. For the side panels, follow
the same procedure as with the tailgate, drill and rivet buttons alternating from one side
to other side of the tub.

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Fi ure 1: Placement of
aluminium rope track.
Ensure channel is above
the tub’s top edge.
Fi ure 2: Placement of
bar bracket

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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, 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.
Fi ure 3: Placement
of rope button is
along panel crease
and vertically inline
with each ring grip.

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3.
Remove tonneau and drill the marks with a 4 mm drill b
it, 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.
Part No: BARA J
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 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
FIT FIT
FIT BAR
BARBAR
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 ti hten the rub 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.
Warnin if you do not fit the tonneau sheath over the bar, the tonneau cover will quickly wear
throu h which is not covered by warranty.
Your Tuff Tonneau is now ready for work.