Tuff Tonneaus 521 Install guide

TONNEAU FITTING INSTRUCTION
Toyota Hilux Extra Cab
1998 to March 2005
Part number: 521
Package includes
1 X Tonneau Cover
2 x Bar Brackets
1 x Tonneau Support Bar
30 x Rivets
3 x Aluminium Rope Track-484mm long ea.
1 x Lock Bracket
1 x Support Bar Sheath
16 x Rope Buttons
1 x Fitting Instructions
4 x Dowel
16 x Anti-abrasive Disc

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 Shown in Diagram A, 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 928mm back from the inside front edge at the top of the tub and
place them as shown in diagram A. (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.
6. To fit round body hooks measure 115mm down from the top edge and line up each hook
individually to each bunji loop starting with the two either side of the tailgate 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.
Diagram A

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.
2.2 TONNO LOCK CONTENTS
-2 X 4MM Aluminium rivets
-1 x Tonno Lock bracket
2.3 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.
3. Remove tonneau and drill the marks with a 4 mm drill bit, place the lock bracket in position and rivet.
Diagram B

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.
Part No: BARADJ
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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Your Tuff Tonneau is now ready for work.