Suffolk SS100 Manual
Build Manual
Suffolk SS100
Suffolk Sportscars
PO Box 100, Woodbridge, Suffolk, IP12 9BA
Roger Williams - 07967 339424 - roger@suffolksportscars.com
Workshops - 01728 745055 - theworkshop@suffolksportscars.com
SS100 Build Manual (Export Edition)
Page 2
Dear Customer,
Suffolk SS100 – OWNERS BUILD MANUAL
We hope that your chosen project of self-building your Suffolk SS100 will be as enjoyable as
driving your car following completion. This Build Manual has been written and upgraded many
times over the 20 years of production. We want you to enjoy every aspect of building your
car. There is great satisfaction in being able to look back on the project and say “I built that
car”.
Over 200 Suffolk cars have been sold to date; 140 have been built by customers at home.
Our emphasis is very much directed towards supplying the parts and assisting self build
owners in the satisfactory completion of their SS100. The Manual is written logically and
without jargon to take you through the build processes to completion. This is Revision 10
and includes technical improvements to the front suspension, body mounting and electrical
circuits; all with many more diagrams.
You are most welcome to visit and revisit us at Woodbridge to learn more, take photographs
and talk to Philip, Michael or myself about the construction of your car. If you are unable to
undertake some elements of the build process yourself, we can do the work on your behalf.
We are here to help and ensure that your build goes smoothly and according to the original
plan.
Yours sincerely,
Roger Williams
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 3
Build Manual for Suffolk SS100 Sports Car
Index
Page
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SS100 Build Manual (Export Edition) Rev 10 November 2013
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SS100 Build Manual (Export Edition) Rev 10 November 2013
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SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 6
1. Introduction
This scope of this manual is to provide all the information necessary to build the Suffolk SS100 sports car. It
assumes that all donor car parts are supplied by Suffolk Sportscars, fully refurbished and built into subunits
ready for assembly, along with all the other parts required for completion ofthecar. If a builder wishes to
refurbish donor parts himself he should contact Suffolk Sportscars.
The skills required to successfully build the car are straightforward and need basic mechanical appreciation
and assembly skills only. Only a few tools over and above what is normally found in the average garage of
an owner who carries out his own routine maintenance are required.
Essential photographs showing chassis build up are included in Appendix 3. A CD ROM with about 100
photographs covering every aspect of the build is available from Suffolk Sportcars for £15 including postage and
packing refundable against a chassis purchase
2. Tools, equipment & ordering of parts
•A single 16 x 8 ft garage is sufficient space to build the car but more room is helpful, plus:
•A Haynes workshop manual for Jaguar XJ6 series I, II, III. (Haynes Ref 0242, ISBN 1-85010-178-7)
•A bench and vice
2.1 Tools Required
•A set of Imperial (3/8” - 1” A/F) and metric (10 - 26mm A/F) spanners - open ended and ring.
•A 1/2” square drive socket set covering 7/16” - 1” A/F and 10 - 26mm A/F.
•A 1/2” square drive torque wrench of 120 ft-lbs capacity.
•A portable electric drill with 1/2” (13mm) chuck & drill bits from 1 - 13 mm in 0.5mm steps.
•Thread cutting tap sets: M3, M4, M5, M6, M8, 2BA, 1/4”, 5/16”, 3/8”, 7/16” UNF & tap wrenches plus
tapping drills 2.5, 3.3, 4.2, 4.0, 5.0, 5.5, 6.9, 8.5 mm.
•Set of Allen keys, metric and Imperial.
•Usual selection of hand tools e.g. screwdrivers, pliers, files, hacksaw, spirit level etc.
•Electrical test meter and leads.
•Electrical crimping pliers.
•Sheet metal snips or nibbler for the bonnet panels. The nibbler type is much easier to use unless the
builder is experienced in sheet metal work.
•Pop rivet tools and a selection of blind rivets.
•4 axle stands rated at 1 tonne.
•A trolley jack. A cheap one will suffice but a 2 tonne model giving a 15” lift is well worth the money.
•
An engine crane of 1-ton capacity is needed to install the engine & gearbox assembly. If Suffolk Sportscars
deliver the assembly, this can be done for you. Otherwise this item can be hired or bought. You will also
need suitable chain and shackles to attach to the engine lifting eyes.
•A dremel hobby type grinding/cutting multi tool – with various attachments.
2.2 Fasteners
Suffolk Sportscars can supply all nuts, bolts and fasteners in acomprehensive boxed &labelled kit. Nut and
bolt sizes are listed within the kit for each operation in the build schedule. Owing to the diversity of
component suppliers both imperial and metric threads are used.
All Jaguar components (with very few exceptions) use unified (imperial) threads, mostly UNF, but UNC is
used for threads in aluminium alloy. Exceptions are steering racks on some later cars where the track rods are
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 7
threaded M14 fine (1.5mm pitch), and the bolts securing the front brake callipers and steering arms, which
are M12 fine (1.25mm pitch). Where metric threads are used on other components they are isometric (coarse
series).
SU carburettors use BSF and BA, while most of the fittings to the windscreen are 2BA.
It is recommended that stainless steel fastenings are used for fittings to the body and for those directly
exposed to dirt, salt etc. from the road. Stainless nuts and bolts in unified threads are difficult to obtain, but
metric are readily obtainable and are used for this reason wherever possible.
It is recommended that all non-stainless fasteners are high tensile nickel-plated. Suffolk Sportscars can
supply all nuts, bolts and fasteners in acomprehensive boxed &labeled kit. Nut and bolt sizes are listed
within the kit for each operation in the build schedule. Owing to the diversity of component suppliers both
imperial and metric threads are used.
All Jaguar components (with very few exceptions) use unified (imperial) threads, mostly UNF, but UNC is
used for threads in aluminium alloy. Exceptions are steering racks on some later cars where the track rods
are threaded M14 fine (1.5mm pitch), and the bolts securing the front brake callipers and steering arms,
which are M12 fine (1.25mm pitch). Where metric threads are used on other components they are isometric
(coarse series).
SU carburetors use BSF and BA, while most of the fittings to the windscreen are 2BA.
It is recommended that stainless steel fastenings are used for fittings to the body and for those directly
exposed to dirt, salt etc. from the road. Stainless nuts and bolts in unified threads are difficult to obtain, but
metric are readily obtainable and are used for this reason wherever possible.
It is recommended that all non-stainless fasteners are high tensile nickel-plated.
2.3 Ordering of parts
Please photocopy the proforma of the customer order form (Appendix 7) and complete as required. Please
date and number your orders sequentially and send them to:
Roger Williams
Suffolk Sportscars Ltd
POBox 100
Woodbridge
Suffolk IP12 9BA
Please keep a copy of your orders for reference purposes.
Parts Delivery Disclaimer
We try to offer the best possible service at Suffolk Sportscars and we are happy to deliver items to your
home or workplace. The driver will assess whether or not he can physically maneuver the items into place
and will only do so if items pass freely through the spaces provided.
Customers responsibility:
1. to ensure that the storage area is already prepared to receive the items prior to their arrival.
2. for the welfare of the goods as soon as they arrive on site.
3. for the welfare of the persons involved in lifting heavy / awkward items.
Once you have ordered your parts and you have a delivery date please make sure you have the space required
ready for delivery, in case of the body delivery please make sure there is sufficient space around the chassis
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 8
for the delivery driver and helpers to get the body in position over your chassis. You will find the body size
measurements in appendix 8.
3. Build sequence & Parts list
There are a number of variations in build sequence to meet individual preferences. Build sequence A is a
guide based on a number of successful customer builds. Build Sequence B is that used by Suffolk Sportscars
when factory building a car. The key difference is that in the factory build sequence B the body is fully
finished and painted before many of the drillings are made and fittings attached. Sequence A takes the more
cautious approach of attaching the body and making all drillings and fittings, then removing the body for
finishing & painting. This means that any mistake in making holes in the body can easily be corrected by
filling and finishing. For further advice, consult Suffolk Sportscars.
The sections in this manual correspond to Build Sequence A. If Build Sequence B is adopted there will be
some changes in sequence and detail.
3.1 Build sequence A
The following build sequence can be used as aguide and or check list as you build your Suffolk SS100, Some
builders prefer to fully build the car and/or cut their own bonnet before disassembling for paint at alocal body shop,
this is fine but you may need to change some of the sequence, itis amuch more cautious approach to fully build
before painting and will take you alot longer to finish your build.
In our experience very few customers damage their cars paint as long you take sensible precautions and always protect
the paint where possible orwhere there is a risk ofdamage.
1. Support the chassis on 4 axle stands.
2. Fit using “Loctite”, the 4 special Suffolk bushes to the chassis, which carry the final drive and rear
suspension subunit. (Before fitting check that the bores of the tubes into which the bushes are fitted are
cleaned of all paint, weld splatter or other obstruction).
3. Set up the rear axle assembly on the floor with the drive shafts horizontal (using a spirit level) & check
the camber of the rear hubs. If not at zero degrees (i.e. vertical), adjust with shims between the brake disc
and the inner universal joint flange.
4. Fit into the chassis, using the upper & lower Suffolk mounting plates, the final drive and rear suspension
subunit.
5. Fit the 4 coils over the shock absorber units.
6. Fit the 2 rear tie bars and spherical “Rose” joints. Adjust tie bars to equal length.
7. Build up the front suspension units using the lower & upper wishbones, stub axle, carrier and hubs from
the donor car.
8. Fit the 2 front coil over shock absorber units and brake calipers.
9. Fit the steering rack using the 3 polyurethane bushes. (Drill the front cross member for the brake pipe
fixings first).
10. Set front wheel alignment approximately.
11. Fit the brake & clutch pedals on the chassis with the cross shaft.
12. Fit the brake servo and master cylinder to the mounting plate on the chassis.
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 9
13. Fit clutch master cylinder & actuating rod.
14. Fit the brake lines to the inside of the long offside chassis rail and via the front cross member to the
nearside front brake.
15. Fit the brake light switch and front brake flexible hoses.
16. Fit the fuel tank sender unit and the fuel tank to the chassis.
17. Fit the fuel pump.
18. Run the 5/16” OD fuel line from the tank to the engine bay via the fuel pump.
19. Fill the fluid reservoir and bleed the braking system.
20. Fit the engine mountings and special bush and mounting to the gearbox.
21. Fit the gearbox mounting plate to the chassis.
22. Using an engine crane install the engine & gearbox subunit into the chassis.
23. Fit clutch hydraulic line and hose connection to the slave cylinder. Bleed the system.
24. Install the Suffolk modified prop shaft.
25. Fit the 6-part stainless steel exhaust system.
26. Paint the radiator matt black & fit electric cooling fan to radiator.
27. Radiator-mounting hoop, alloy radiator core (central to body) and top & bottom hoses.
28. Initial wiring.
29. Splined hubs, dummy brake drums and wheels and tyres.
30. Lift on the body.
31. Bolt down the body.
32. Test fit doors.
33. Final mounts and spacers.
34. Scuttle bracket and short stays.
35. Cut or test fit bonnet.
36. Body paint preparation and checks.
37. Refit body and doors.
38. Refit bonnet.
39. Handbrake cable.
40. Seat runners and floorboards.
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 10
41. Handbrake lever.
42. Remove floorboards for staining and refit.
43. Gearbox and prop-shaft covers.
44. Alloy floor plates and sealing floorboards.
45. Windscreen and wipers.
46. Front valance and dummy starting handle eye.
47. Headlamp bar.
48. Lamp bar stays.
49. Wing stays.
50. Steering column.
51. Throttle pedal.
52. Choke cable.
53. Door latches and striker plates.
54. Rear lamp brackets.
55. Spare wheel brackets.
56. Rear reflectors.
57. Dummy fuel vent and hood support blocks.
58. Fuel cap and adaptor.
59. Hood mount spindles.
60. Heater.
61. Wing beading.
62. Running board strakes.
63. Final wiring.
64. Interior trimming.
65. Weather gear.
66. Steering wheel.
67. Number, GB and chassis plates.
68. Luggage rack.
69. Seatbelts.
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 11
70. Tuning and testing.
71. Road preparation.
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 12
3.2 Parts List
Any items not ticked in the SUPPLIED column are not in stock and will follow shortly.
DATE
LOCATION
CUSTOMER NAME BUILD
No.
DELIVERY
DATE
SS REF No.
SUPPLIED
REQUIRED
SECTION 1 CHASSIS BUILD UP
Page 1
DESCRIPTION
★
Special order
Donor car component package
Strip/prepare/paint donor components
001
Chassis painted + black powder coating
002
Radiator hoop
003
2 long stays + 2 short stays + 2 wing stays
004
Differential mountings x 3 (2 lowers often part of rear axle - 077)
005
Metalastic bushes x 4
006
Gearbox mounting plate
007
Spare wheel carrier + spacers x3
008
Pedal shaft, washer, bolt & split pin.
009
Brake & clutch pedals + 2 tops + rubbers & Throttle pedal + brkt
010
Tie bars x 2 complete with bushes and rose joints
011
Handbrake assembly inc. cable
012
Prop-shaft (specify gearbox type)
013
Fuel tank + straps + rubber strips + drain bung
014
Fuel tank sender unit – bent to correct profile
015
Alloy radiator + Fan thermo switch + Electric fan fitted +15lb rad
cap
016
Radiator lower mounting rubbers x2 + overflow hose + bottom
hose
017
Andre Hartford dummy x2 + stars and dials
018
Servo + master cylinder + 4 spacers + hose & clips
019
Steering rack – modified long or short turret
020
Track rod ends x2 (metric or imperial)?
021
Rack mounting poly bush kit
022
Front shock absorber mounting plates x 2
022a
Bolt on steering lock stops (fit with 022)
023
Front shock absorber spacers x 4
024
Front shocks + springs x 2 fitted together
025
Front brake flexible hoses + nuts x 2
026
Clutch flexible hose + nuts
027
Clutch master cylinder + pushrod
028
Brake pipe set – 11 piece
029
Brake light switch + copper washer
030
Brake unions 1 x 3way + 1 x 4way
031
Fuel line set + nut & olive + hose clips x6
032
Fuel pump
033
Fuel filter - glass
034
Front lower wishbones x 1LH + 1RH
035
Front lower wishbone shafts x 2 + castle nuts & split pins
036
Front serrated washers x4 + thin washers x2
037
Front lower wishbone castor spacers (SS) x2
038
Front lower wishbone bushes x4
039
Front bottom ball joints x2
040
Front upper wishbones x4 (curly or straight)?
041
Front upper wishbone rubber bushes x4
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 13
SS REF No.
SUPPLIED
REQUIRED
SECTION 1 CHASSIS BUILD UP Page
2
DESCRIPTION
★
Special order
042
Front top ball joints x2
043
Front upper wishbone inner mounting shaft x2
044
Front chrome washers x8
045
Front upper caster shims x6
046
Front wheel bearing car set (early or late type)?
047
Front upright s/axle + washer, nut & cap
048
Front steering drop arms 1LH + 1RH
049
Front brake pipe support brackets x 2
050
Front hubs x 2
051
Front brake discs x 2
052
Front calipers x 2 + special mounting bolts & lock wire
053
Front brake pads x 2
054
Rear shocks + springs x 4
055
Rear shock mounting pins x 4 + spacers & washers + springs
056
Rear hubs fully built up x 2 (labour)
057
Rear hubs x 2
058
Rear hub carriers x 2
059
Rear oil seal tracks rear x 2 large + 2 small
060
Rear seals and taper bearings x 4ea + tubes x 2
061
Rear wheel bearing kits + shims x 2
062
Rear tie bar brackets x 2
063
Rear differential + top bolts + breather
Ratio:
064
Rear differential side mounts x 2 + tubes x 2 + bolts
065
Rear drive shafts shortened x 2
066
Rear lower arms shortened x 2
067
Rear discs x 2
068
Rear brake pads x 2
069
Rear calipers x 2 + mounting bolts
070
Rear handbrake calipers x 2 (inc. pads) + springs x 2
071
Rear universal joints drive shaft x 4
072
Rear needle rollers x 8 + sleeves x 4
073
Rear washers/seals/rings x 8
074
Rear wishbone pins x 2 inner + 2 outer
075
Rear driveshaft flanges x 2 inner + 2 outer
076
Rear driveshaft shims x 14
077
★
Build up whole rear end + (assy labour) includes 056 labour
All items 056-076
078
Nut and bolt kit. Labeled for build-up sections
079
Splined hubs, x 5. 3 x LH, 2 x RH
080
Spinners, x 5. 3 x LH, 2 x RH, chromed with SS logo
081
Brake drums, dummy, x 4.
082
Wheel nuts, x 20. Donor/ new. Machined
★
Delivery to: Date of Delivery:
Delivery Diesel or courier costs:
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 14
DATE
LOCATION
CUSTOMER NAME BUILD No.
DELIVERY
DATE
SS REF No.
SUPPLIED
REQUIRED
SECTION 1a ENGINE GEARBOX
Page 3
DESCRIPTION
★
Special order
083
Jaguar XJ6 engine:- Donor or Remanufactured by
______________
3.4 3.8 4.2
084
Engine mountings, SS made steel units, x 2
085
Engine mounting rubbers, x 2
086
Alternator 18 ACR, donor unit,/ rebuilt unit.
087
Alternator bracket, SS
088
Alternator adjuster
089
Fan belt – 913 or 925
090
Starter motor and solenoid, donor unit / rebuilt unit. + bolts
091
D type plug lead holder made to fit offside cam cover.
092
Top hose + bypass hose
093
Distributor – Standard Points type or
★
Electronic Ignition type
094
Coil, donor / new. & a set of HT Leads
095
Air cleaners x 2.
096
Throttle linkage, donor, as fitted, SS made/modified units.
097
Choke cable
098
Engine driven fan, plastic.
099*
Electric fan and mounting kit - *if required separate from radiator
100
Exhaust manifolds, x 2 refurbed donor
101
★
Polished Stainless Steel (2 part) 6-branch exhaust manifolds
102
Water pump. Donor unit / rebuilt early type unit.
103
Suffolk water jacket casting + gasket.
104
Oil filter housing + filter to suit. Type:
105
Inlet manifold
106
Carburetors x 2, donor units / rebuilt units. Size 13/4, 17/8, 2 inch.
107
Cam covers - polished Jaguar Mk II type, x 2, polished.
108
Oil filler cap with SS logo, alloy / original type chromed
109
Flywheel, donor unit / new unit / recon unit + bolt set
110
Clutch cover and driven plate + carbon thrust bearing – set
111
Gearbox donor / rebuilt. 4 speed + o/d or
★
5 speed or automatic.
112
Gearbox mounting rubber + gearbox mounting bush, by SS
113
Rebuild overdrive unit.
114
Bell housing. Modified by SS + gearbox bolt set & Cover plate
115
Clutch fork + pushrod
116
Right angled drive for 4speed o/d gearbox
117
Speedo cable (to suit 111 & 116)
118
Clutch slave cylinder & spring + tab washer & Banjo pipe
119
Gear lever and alloy knob.
120
Assemble engine with bell housing, gearbox & overdrive.
120a
★
Fit engine into customers chassis; Bring our engine crane
121
Exhaust system, with mountings & fixings. Standard or
★
special?
122
Road wheels, 18inch x 5. Silver painted, / chromed / special
stoved.
123
Tyres 550 x 18, x 5 Blockley. Plus tapes & tubes.
124
Fitting tyres to wheels & balancing
★
Delivery to: Date of Delivery:
Delivery Diesel or courier costs:
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 15
DATE
LOCATION
CUSTOMER NAME BUILD
No.
DELIVERY
DATE
SS REF No.
SUPPLIED
REQUIRED
SECTION 2 BODY & FITTINGS
Page 4
DESCRIPTION
★
Special order
125
Bodywork, in GRP, chassis fitted with doors hung
RHD or ★LHD
★
Wing rivets?
126
Valance made in GRP or
★
Alloy.
127
Bonnet set - alloy, 4 part. Supplied with 3 hinges & 2 end pivots.
128
Alloy bonnet rivets x16 + 2 spare
129
★
Fit bonnet to body and to radiator shell – labour.
130
Starting handle eye – chromed + fixings.
131
Ripaults bonnet catches SS pattern- chromed, x 4.
132
Bonnet hooks - under bonnet, x 4. + fitting sheet
133
Bonnet studs, x 4.
134
Radiator shell - chromed.
135
Radiator grille- chromed.
136
Radiator cap and handle - chromed.
★
Special mascot?
137
Radiator badge and 2 enamelled logos. Colour?
138
Radiator shell brackets x 2
139
Radiator/body bonnet tape.
140
Headlamp bar with ‘100’ logo - chromed.
141
Headlamp bar fitting kit
142
Headlamp stays, eyes & knuckles - stainless x 2.
143
Type 40 Headlamps - stainless, x 2.
144
Type 40 mounting posts, inserts, lenses & stone guards x 2.
145
Sealed beam, 7inch light units x 2, RHD / LHD?
146
Spot lamps to fit with Type 40 Lamps + brackets.
147
★
Lucas QK596 Headlamps - chromed x 2 (special order).
148
★
Lucas QK596 mounting posts x 2
149
★
Lucas Spot lamps to match QK596 Lamps + brackets.
150
Lucas sidelights - chromed, used as indicators x 2, + orange bulbs.
151
Lucas “Owl’s Eye” rear lights - chromed, x 2. With bulbs fitted.
152
Rear lamp brackets x 2.
153
Set of flexible lamp conduits x 4.
154
Rear reflectors x 2.
155
Rear fog light.
156
Reverse light.
157
Horns - chrome fronts x 2.
158
Wiring loom, relays and fuses.
159
Door locks, covers & Door striker plates x 2.
160
Hood side mounts to body x 2.
161
Hood rests - rear x 2.
162
Dummy tank vent curly - chromed.
163
Aston Fuel cap + adaptor plate, fuel hose & jubilee clips x 2.
164
Running board strakes x 10, cut to length with rubber inserts.
165
Heater + fitting kit.
166
Interior mirror + fixings.
167
Seat runners, modified donor x 4.
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 16
SS REF No.
SUPPLIED
REQUIRED
SECTION 2 BODY & FITTINGS
Page 5
DESCRIPTION
★
Special order
168
Seat frames with bases and backs – metels black painted x 2.
169
Seat foams, x 2.
170
Door check strap holders - chromed x 4
171
Rear compartment locks x 2
172
Floorboard set including angle brackets & clutch access cover.
173
Alloy seatbelt anchor covers
174
Transmission covers x 2. 4speed+o/d or
★
5speed, / automatic?
175
Steering column upper - donor modified + lock & key,
176
Steering column lower shaft + UJ‘s x 2
177
Indicator stalk +dip +flasher + horn switching.
178
Steering wheel - MotoLita + alloy boss or
★
old style black
179
Wiper motor - 130_ sweep + rack and spindles + nuts.
180
Wiper blades, arms and pegs, x 2ea.
181
Wiper ‘Z’ mounting to chassis plate & ‘U’ bracket
182
Dashboard grab handle - chrome.
183
Instrument set. Tacho, speedo, oil, water, fuel, amps & fittings
184
Pull switches, x 3.
185
Side/headlamp rotary switch. Old style Jaguar Mk II modified by SS
186
Fuel, main/reserve, dummy control knob
187
Ignition switch.
188
Starter button
189
Auxiliary light switch to operate fog lamps - red or green LED ?
190
Dashboard warning lamps, 2 x green, 1 x orange/red
191
12v Phone charger socket
192
Enamel Union Jack bonnet badges x 2.
193
SS door sill nave plates - chromed x 2.
194
Seatbelt set new or donor + fixings & posts
195
Battery tray and clamp kit
196
Steering column st/stl bulkhead shroud + rubber
197
Door seal – self adhesive black neoprene rubber
SECTION 2a: PAINTWORK
198a
★
Paint bodywork and bonnet
198b
Transport to and from paint shop
198c
Touch-in paint pot
Additional items:
199a
Battery cut off switch
199b
★
Engine turned dash cover panel – drilled
199c
Hidden switch panel (for 12v charger socket + extra switches, etc)
199d
Hazard warning lamp switch & relay unit
Note to S.S.– Check if body needs to be trimmed to suit stl manifold
★
Delivery to: Date of Delivery:
Delivery Diesel or courier costs:
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 17
DATE
LOCATION
CUSTOMER NAME BUILD No.
DELIVERY
DATE
SS REF No.
SUPPLIED
REQUIRED
SECTION 3 FINISHING COMPONENTS
Page 6
DESCRIPTION
★
Special order
200
Windscreen, SS folding, glazed, chromed.
201
Windscreen fitting kit
202
Aeroscreens x 2 with fixings
203
Wind wings x 2 with fixings
204
Wing mirrors x 2 with fixings
205
Hood frame, painted black
206
Hood in Black mohair, fitted with timber bow.
207
Hood clips & complete hood fitting kit
208
Hood bag in Black mohair
209
Tonneau cover in black mohair
210
Side screens, x 2 in black mohair with flexible windows + bag
211
Luggage rack + brackets & fitting kit
212
★
Luggage trunk & black cover + fitting kit
SECTION 3a: INTERIOR, TRIM, LEATHER & CARPETS
213
★
Full Interior trim set - made with seats, doors, locker, carpets - fully
fitted by our trimmer.
214
★
Part Interior trim set - 2 seats and 2 door panels, customer to fit
remainder with carpet & leather material supplied.
215
Supply leather only
216
Supply carpet only
SECTION 3b: REGISTRATION ITEMS
217
Front number plate - oblong
218
Rear number plate - square
219
GB plate - square
220
Chassis plate
221
Tax disc holder
222
Badge bar & 4 badge buckles
Any other items:
223a
Wing beading kit
223b
Hidden storage bin located above rear axle
★
Delivery to: Date of Delivery:
Delivery Diesel or courier costs:
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 18
4. Chassis, suspension, steering & final drive
You will need the following parts for this operation:
• Chassis kit comprising:
•MIG welded box section chassis.
•Gearbox mounting plate.
•
Differential mounting plates (3 will be attached to differential if been built by Suffolk Sportscars).
The below parts are not required until your body is fitted,
•Radiator hoop.
•Radiator hoop stays (long) - (2)
•Dashboard stays (short) - (2)
•Front wing stays (2)
Upon delivery of the chassis locate it in the centre of the build area with maximum access from all four sides.
Three people, two at the rear and one at the front can easily lift the chassis. Place the chassis on the four axle
stands with the main longitudinal 2” x 4” members parallel to and about 15” above the ground. Placing
cardboard or cloth between the axle stands and the chassis will avoid damage to the powder coating.
The chassis is stamped clearly with its chassis number behind the offside front upper wishbone. Check that
this is so as it is a legal requirement. See Appendix 9 for a detailed drawing of the chassis.
4.1 Rear suspension and final drive
You will need the following parts for this operation:
•4 special rubber “Metalastic” bushes for mounting the differential unit.
•A 6” length of 12mm studding, washers, nuts and a tubular spacer or similar, see Figure 1.
•Loctite thread lock.
•The assembled final drive and rear suspension subunit comprising differential, rear discs, main
calipers, handbrake calipers, brake pads, handbrake pads, return springs, lower wishbones, drive
shafts, hubs, and lower differential mounting plates.
•Coil over shock absorber units with springs fitted (2).
•2 upper rear shock absorber mounting spindles (Suffolk manufacture), washers & nyloc nuts.
•2 lower shock absorber mounting spindles from donor car (modified), washers & nyloc nuts.
•4 spacers 5/8” ID x 3/8” for mounting the two rear shock absorbers ahead of the drive shafts.
•2 tie bars with Rose joints fitted at one end, rubber bushes at the other.
•1/2” UNF x 31/2” bolts (4).
•1/2” UNF x 4” bolts (2).
•1/2” UNF x 21/2” bolts (2).
•1/2” UNF nyloc nuts (16).
•1/2”ID x 11/2” OD “mudguard” washers (2).
•1/2”ID x 11/8” OD “mudguard” washers (8) – 2 with a 3mm hole drilled near the OD.
•4 special countersunk 1/2” UNC bolts from the donor car for attaching the final drive to the upper
mounting plate.
•0.8mm diameter stainless steel locking wire.
•Camber setting spacers as needed (usually 2 inner and 6 outer).
4.1.1 Prepare chassis for bushes
Firstly remove all powder coating (paint) from the inner bore of the 4 mounting points (2 each in the upper &
lower cross beams respectively) for the special rubber bushes with paint stripper (e.g. Nitromors), wire
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 19
brushes and emery paper. It is important that the bores are a clean, smooth metal surface before attempting to
fit the bushes.
4.1.2 Fitting bushes
Clean the surface of each bush and coat sparingly with Loctite. Using the studding, spacer, washers and nuts
as in figure 1 or similar, press the bushes home until they are centralised in the cross member.
4.1.3 Differential mounting plate
Using two 1/2” UNF x 3 1/2” bolts & nyloc nuts assemble the top differential mounting plate to the chassis
upper cross member via the rubber bushes. The plate needs to be mounted with the flat face forward.
4.1.4 Rear axle set up
Set up the rear axle assembly on the floor with the drive shafts horizontal using suitable packing pieces and a
spirit level. Referring to fig 2, fit shims between the brake discs and the inner universal joint flanges to set
the rear hubs vertical using the spirit level. Tighten the inner drive joint flange nuts to 55 ft-lbs. If you’ve
received your axle fully built this will have already been done for you.
4.1.5 Installing axle
Next offer up the rear suspension & final drive subunit to the chassis (See photo 3). The help of 2 colleagues
is required. Place the subunit on a trolley jack or another kind of lifting bed capable of taking the weight,
supported under the flat lower differential mounting plate. With a person at each hub to steady the unit,
position it such that the 4 tapped holes in the top of the differential mate with the 4 holes in the top mounting
plate. Screw in the 4 countersunk bolts loosely at this stage.
4.1.6 Lower mounts
Using the remaining two 1/2” UNF x 31/2” bolts, nyloc nuts and the 1/2”ID x 11/2” OD “mudguard”
washers, attach the lower differential mounting plate to the chassis lower cross member. Fit washers as
necessary between the mounting plate and the chassis so that when the 4 top countersunk bolts are tightened,
alignment is maintained, and undue stress is not applied to the differential body or bushes. Install the large
“mudguard” washers between the front face of the bush and the nyloc nut. This is to ensure, in the unlikely
event of the bush becoming loose in its bore, that the lower mounting plate remains captive.
4.1.7 Tightening and wiring
Using spanners and finally a torque wrench tighten the 4 countersunk differential attachment bolts to 75 ft-
lbs (since there is little access for a torque wrench on some of the bolts use best judgement with a spanner),
and the 4 attachment bolts to the chassis to 40lb-ft. Using the 0.8mm S/S wire lock together the 4 special
countersunk 1/2” UNC bolts by passing the wire through the drillings in the bolt heads before twisting the
wire and passing through the next bolt head, special pliers are available to help make this tight and tidy.
4.1.8 Differential oil
Make sure that the differential unit has been filled with fresh hypoid oil (refer to Appendix 4 for the correct
grade). The filler port is easy to access now but much more difficult after the fuel tank has been fitted. The
filler plug is also the level, fill until oil is level/just runs out of the threaded plug hole. It is a good idea to
write a note somewhere to say the oil has been filled to save having to check later on.
4.1.9 Assembling Coil over dampers
Next fit the 4 coils over shock absorber units. It is clear which is the rear versus the front as there are 4 of the
former and 2 of the latter. Assemble these if not already done and set the spring height and damper setting to
the base settings advised in figure 23.
4.1.10 Coil over damper mounting spindles
First check the fit of the upper spindles (5/8” diameter) with the attachment tubes welded into the chassis.
They should be agood sliding fit. Do not use force to fit them above alight tapping with acopper mallet. If
they are tootight, which is unlikely, then theonly reliable way to correct this is byreaming with a 5/8”
reamer. Please contact Suffolk Sportscars who may be able to supply one on loan if you need one.
SS100 Build Manual (Export Edition) Rev 10 November 2013
Page 20
4.1.11 Coil over damper mounting with spacer
The 5/8” ID x 3/8” spacers should be fitted inside the upper and lower bushes on the forward most units.
Ensure that a 1/2”ID x 11/8” OD “mudguard” washer is fitted on the outside of each shock eye to ensure that
they remain captive in the event of rubber bush failure. Fit the two washers with the 3mm holes drilled near
the edge to the forward upper mounts, these holes are to retain the handbrake return springs.
Tighten the 8 nyloc nuts to 35lb-ft.
4.1.12 Rear tie bars
Fit the rear end of each tie bar to the bracket attached to each rear hub using the 1/2”UNF x 21/2” bolts &
nyloc nuts. Fit loosely at this stage. By screwing the Rose joints in or out of the tie bar, set them so that the
two 1/2”UNF x 4” bolts fit easily through the attachment point on the chassis to the eye of the joint, and the
lengths of the two tie bars are equal. This should be done with the rear suspension set such that the drive
shafts are horizontal. This sets the rear wheel alignment approximately true. The bolt should be fitted from
the inside so that the nut faces outward. This allows the Rose joint to be detached to adjust rear wheel
alignment. (With the bolt fitted the other way the body would prevent it being withdrawn). Alignment should
be checked and reset as necessary at a garage with optical alignment equipment at a convenient time before
road running the car. Now tighten the 4 tie bar fixings to a torque of 40 lb-ft.
4.1.13 Handbrake return springs
Install the handbrake caliper return springs between the calipers and the drilled washers (photo 3), these may
need holding in a bench vice and pre expanding a little before they will fit nicely.
4.2 Front suspension.
You will need the following parts for this operation:
a) Reconditioned from the donor car:
•Lower wishbones (2) Upper wishbones (2) - the wishbones of some early XJ6’s were different from
the majority, see figure 4 and the foregoing text
•Stub axle and stub axle carrier (2)
•Upper part of disc protector (to which the brake hose attaches). The lower part can be discarded.
•Steering arms (2)
•Brake callipers (2)
•Front hub & brake disc assembly plus washer, castellated nut & end cap (2 of each)
•Castor adjusting shims (2 sets)
•3/8”UNF upper ball joint bolts (21/2” & 33/4” in length, 2 of each)
•Upper wishbone pivot shaft (2)
•Lower wishbone pivot shaft (2)
•Dedicated bolts for securing brake callipers and steering arm to hub axle carrier (6)
Note : These bolts are specials, some having metric threads. Do not try to replace them with
standard bolts.
•A 6” length 12mm studding, washers, nuts and a tubular spacer see Fig 1
b) Plus the following new items:
•Special spacers (13/16” ID x 3/8”) for mounting lower wishbones. (2)
•Front brake pads (4)
•Upper ball joint (2)
•Lower ball joint (2)
•Lower wishbone bushes (4)
•Upper wishbone bushes (4) and chrome washers (8)
•Mounting plate for shock absorber to lower wishbone (2)
•Coil over shock absorber units (springs already fitted) - (2)
•Brake calliper setting shims as required
•Dummy André Hartford shock absorbers (2)
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