Tuff Tonneaus 325NSB User manual

TONNEAU INSTALLATION INSTRUCTION
D22 Navara 4WD ST-R Dual Cab
Without Sports Bars
Oct 2009 – Jun 2015
Part number: 325NSB
Package includes
 1 X Tonneau cover  2 x Bar Brackets (300474)
 1 x Tonneau Support Bar (300516)  26 x Rivets (300482)
 3 x luminium 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 Dowel
 1 x Warranty Card

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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 .............................................................................................................. 6
2.3 FITTING TONNO LOCK ................................................................................................................... 6
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 PROCEDURE
1.2 TONNEAU COVER INSTALLATION PROCEDURE1.2 TONNEAU COVER INSTALLATION PROCEDURE
1.2 TONNEAU COVER INSTALLATION PROCEDURE
1. Using two pi c s of dow l, join th 3 aluminium rop tracks tog th r. Plac th oth r 2
pi c s of dow l in th nds of th now join d rop track.
2. R st th aluminium rop track on th sid rails as Shown in Diagram A, and push
forward to th v rtical fac of th tub.
3. Using a 4.5 mm drill bit, drill 6 hol s 50mm from th nd of ach of th aluminium rop
tracks into th front of tub.
4. Onc all th hol s hav b n drill d, r mov th dow lling pi c s. Squ z silicon
along th back of th rop tracks and pop riv t into plac .
5. Place the bar bracket 725mm rear from the inside edge of the front of the tub and 12mm up
from the bottom lip, drill and rivet in place.
6. Slid th front of th tonn au cov r through th aluminium rop track s ction.
7. N atly lay tonn au out ov r support bar and tub in th install d position. Fast n all collars
around sports bar l gs with th pr ss studs.
8. To fit th rop buttons to th tailgat , mark two v rtical lin s just b low th form lin on
th Tailgat , 65mm and 482mm in from th RHS dg of th Tailgat . Align th top dg
of th Buttons with th low r dg of th form lin , and th c ntr of th Button hol with
th v rtical lin s. Onc in position us th button as a guid and drill a 4.5mm hol
through th Tailgat .
Repeat Step 8. for the LHS
9. To fit rop buttons to th sid s, mark v rtical lin s just b low th form lin , 50 mm, 392
mm, 736 mm, 1084 mm, 1429 mm from th front dg of th tub on th LHS.
10. Align th top dg of th Button with th low r dg of th form lin , and th c ntr of
th Button hol s with th v rtical lin s.
11. Onc in position us th button as a guid and drill 4.5 mm hol s through th sh t
m tal.
12. ttach the Buttons to the Tub, using the 4 mm rivets.

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Figure 1
Placement of aluminium
rope track. Ensure channel is
above the tub’s top edge.
Figure 2
Placement of rope button is
on tailgate panel crease as
per measurements.
Figure 3
Placement of rope button is
on the side, is under panel
crease as per
measurements.

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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.

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You
will need to buy a small Padlock
-
m
ake sure the padlock will go thr
ough 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.
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)

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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.