Tuff Tonneaus Bunji Ute User manual

TONNEAU INSTALATION INSTRUCTIONS
F250/350 CREW CAB TONNEAU, 2001-CURRENT
Part number: 140
TOOLS REQUIRED
Rivet gun, Drill, 4.5mm Drill bit, Measuring tape, Silicon sealant, Anti-corrosive primer.
CONTENTS
□1 X Tonneau cover □4 X Bar Brackets
□2 X Tonneau bar adjustable □22 X Buttons
□3 X Aluminium Rope Tracks □36 X Large rivets
□1 X Tonneau lock kit including 2 large rivets □4 X Pieces of Dowell
Checked by_____________________ Date______________________
Some items in the fitting kit may not be required
All fitting kits are weighed to ensure accurate quantities.
INSTALLATION PROCEDURE
Note: To prevent corrosion apply an anti-corrosive primer to all holes drilled
1. Using two pieces of dowell, join the 3 aluminium rope tracks together. Place the other 2 pieces of
dowell in the ends of the now joined rope track.
2. Rest the aluminum 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 683mm back from the inside front edge for the first one then 1367mm
from the inside front edge for the second one and place them as shown in diagram A. (5mm down
from top edge of tub) drill and rivet using two rivets for each Bar Bracket. Install support bar
according to supplied instructions.
6. To fit round body hooks to car, pull tonneau tight and squeeze bunji loop together draw a mark at the
bottom of bunji , this is the height to drill the holes for round body hooks (sides may be different
height to the back). 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 body hooks alternating
from side to side.
CARING FOR YOUR TONNEAU
Apply bee's wax or Dri-lube to stitching a few times a year, as this will maintain the tonneau's
waterproofing ability and prevent the stitching from degrading. Use a mild detergent and soft
scrubbing brush to clean tonneau.
Never drive without tonneau support bars in place as flapping can cause a delaminating
effect on the material.
"Tonneau is not designed to be used as a load restraint"

Tonno Lock
INTRODUCTION
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.
BASIC TOOLS REQUIRED
Rivet gun, Drill, Torch, Marking Pencil/Pen. You will need to buy a small Padlock- make sure
the padlock will go through the hole on the Tonno lock.
TONNO LOCK CONTENTS
2 X 4MM Aluminium rivets
1 x Black Tonno Lock bracket
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.
Your Tuff Tonneau is now ready for work.
Tonno Lock is not supplied with the Blank Tonneau Covers

TUFF TONNEAU
Multi-Fit Support Bar
Part No - BARADJ
INTRODUCTION
The Tuff Tonneau MultiFit Support Bar is designed to fit almost all Utes on the Market, from Suburu
Brumbys to Cab Chassis aluminum trays.
BASIC TOOLS REQUIRED Drill, 4mm drill bit
CONTENTS
1 x hollow bar centerpiece
2 x grub screws
2 x solid bar end piece
1 x Tonneau bar sheath
INSTALATION PROCEDURE
STEP 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 were you will drill a hole to the depth of
about 1-2mm (do not go any further)
STEP 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.