TONNEAU COVER FITTING INSTRUCTION
Proton Jumbuck Dual Cab
2003 – 2011
Part Number: ATB01138
1.
TONNEAU COVER FITTING
NOTE: Read entire instructions prior to start.
1.1 BASIC TOOL REQUIRED
Drill, 4mm Drill Bit, Tape Measure, Rivet Gun, Marking Pencil / Pen, Clear Silicone / Silicone Gun
1.2 CONTENTS
1 x Tonneau Cover
3 x Aluminum Rope Track
2 x Bar Brackets
28 x Rivets
1 x Tonneau Support Bar
14 x Rope Buttons
2 x Alum sealing angles
4 x Pieces of Dowell
1.3 TONNEAU COVER INSTALLATION PROCEDURE
NOTE: Remove swarf and apply Rust Inhibitor to all drilled holes prior to riveting.
1.
Place aluminum sealing angle as shown in Figure 1, using two rivets per angle and seal either
side with silicon.
2.
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. Sit the dowel on top of the sealing angles.
3.
Ensure the channel is above the lip’s top edge, so the front bead of the tonneau can slide
through from the side. See Figure 1. Using a 4mm 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.
Mark a position 800mm from the inside edge of the front face of tub towards the rear and
5mm down from the top lip of the tub. Centrally locate the bar bracket over this position and
drill and rivet bracket into place. See Figure 2. Repeat for other side of tub. Fit tonneau
support bar to bar brackets.
6.
Slide the front of the tonneau cover through the aluminum rope track section. You will need
someone else to reach across and help pull the tonneau through the rope track. Position the
self-adhesive Velcro strip on the tub as shown in Figure 1 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.
