Tuff Tonneaus Colorado Dual Cab with Headboard 250 Install guide

TONNEAU FITTING INSTRUCTION
Colorado Dual Cab with Headboard
2003 –July 2012
Part number: 250
Package includes
1 X Tonneau Cover
2 x Bar Brackets
1 x Tonneau Support Bar
25 x Rivets
1 x Support Bar Sheath
1 x Lock Bracket
1 x Fitting Instructions
18 x Rope Buttons
18 x Anti Abrasive Discs

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. With a pencil mark the inside edge on each side of the tub at 650mm from the inside front face
of tub towards the rear on each side. Centrally locate the bar bracket over this position and
align the top of the bar bracket 5mm down from the top edge of the tub and drill and rivet
bracket into place. See Figure 1. Repeat for other side of tub. Fit tonneau support bar to bar
brackets.
2. Fit the 3 Plastics at the front of the cover onto the front of the headboard.
3. Ensure tonneau is centred. To fit the rope buttons to the tub, start with the tailgate, vertically
line up each button to each bunji loop starting with the two either side of the tailgate handle.
The height for the buttons on the tailgate is 175mm down from the inside edge of the tailgate.
Work from the centre out, alternating from side to side. Attach each bunji to the button as it is
fitted.
4. To fit the rope buttons to the sides vertically line up each button to each bunji loop starting from
the rear bunji loop, alternating from side to side working towards the front. The height for the
side rope buttons are all measured down 165mm from the TOP INSIDE EDGE of the tub. Attach
each bunji to the button as it is fitted.
NOTE: All measurements are to be taken from the TOP INSIDE EDGE of the tub.
5. 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.

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.
Figure 1: Placement of
bar bracket
650mm

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
Please complete our 2 minute feedback section as we strive to constantly
improve for our customers.
Your Tuff Tonneau is now ready for work.