Tuff Tonneaus Ford PX Ranger Dual Cab User manual

TONNEAU INSTALLATION INSTRUCTION
Ford PX Ranger Dual Cab
Nov 2011-May 2013
Part number: 142SB
Package includes
 1 X Tonneau cover  2 x Bar Brackets (300474)
 1 x Tonneau Support Bar (300516)  30 x Rivets – ST (300482)
 3 x Aluminium Rope Track-403mm long ea.  1 x Lock Bracket
 1 x Support Bar Sheath  18 x Rope Buttons (300473)
 1 x Fitting Instructions  4 x owel
 1 x Warranty Card  2 x 100mm angle pieces (S-0047)

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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
1.2 TONNEAU COVER INSTALLATION 1.2 TONNEAU COVER INSTALLATION
1.2 TONNEAU COVER INSTALLATION PROCEDURE
PROCEDUREPROCEDURE
PROCEDURE
1. Remove the front bolts from the sports bar brackets on both sides of the ute.
2. Place a sealing angle between the tub and the bracket and using a straight edge level
the seal plates and replace and tighten the bolts Refer figures 2, 3 & 4.
3. 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 and sit the end dowels on the
seal plates to position the rope track. See Figure 1.
4. sing 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.
5. 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.
6. Mark a position 720mm from the inside edge of the tailgate of tub towards the front.
Centrally locate the bar bracket over this position and the top edge of the bracket 5mm
down from the top lip of the tub and drill and rivet bracket into place.. Repeat for other
side of tub. Fit tonneau support bar to bar brackets.
7. Slide the front of the tonneau cover through the aluminium rope track section. Position
the self-adhesive Velcro strip on the tub as shown in Figure 2 so that it aligns with the
Velcro strip sewn into the tonneau cover. Repeat for other side of tub. Note: Clean this
area with soapy water or methylated spirits prior to adhering the strips to ensure the
surface is free from any dirt, oil and grease.
8. To fit the rear rope buttons, ensure the cover is centralized with the tailgate and line up
each bunji vertically, measure 474mm up from the botto edge of the tailgate to the
centre line of each bunji and using a 4mm drill, drill and rivet each button into position.
9. To fit the side panels rope buttons line up each bunji vertically, starting from the rear
bunji, closest to the tailgate, measure 145mm down from the inside edge See Figure 5
drill and rivet button alternating from one side to other side of the tub. For the next button,
measure 150mm down from the inside edge drill and rivet button alternating from one
side to other side of the tub. For the next button, measure 155mm down from the inside
edge drill and rivet button alternating from one side to other side of the tub. For the next
2 buttons, measure 160mm down from the inside edge drill and rivet button alternating
from one side to other side of the tub and for the last button, measure 160mm down from
the inside edge and 50mm back from the cabin end of the tub (so the bunji is on an angle
pointing forward) drill and rivet button on both sides of vehicle.

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10. Attach the tonneau cover to all rope buttons.
11. Fitment is complete.
Measure down
from inside edge
and place button
on centre of
measurement.
Figure 1
Placement of
Placement ofPlacement of
Placement of Rope track
Rope trackRope track
Rope track
Figures 2, 3 & 4
Placement of side sealing
angles
Figure 5
Placement of rope button

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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.
3. Remove tonneau and drill the marks with a 4 mm drill bit, place the lock bracket in position and
rivet.

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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 BAR
FIT BARFIT BAR
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 s rews . 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 over will qui kly wear
through whi h is not overed by warranty.
Your Tuff Tonneau is now ready for work.