Build Manual Suffolk SS100 Suffolk Sportscars PO Box 100, Woodbridge, Suffolk, IP12 9BA Roger Williams - 07967 339424 - firstname.lastname@example.org Workshops - 01728 745055 - email@example.com...
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.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Build Manual for Suffolk SS100 Sports Car Index Page 1. Introduction
6 2. Tools,
SS100 Build Manual (Export Edition) Rev 10 November 2013 12.5 Seat
6 7 12.6 Chassis
6 7 13
SS100 Build Manual (Export Edition) Rev 10 November 2013 Appendix
9 9 ...
Rev 10 November 2013 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 of the car.
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.
Build sequence A The following build sequence can be used as a guide 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 a local body shop, this is fine but you may need to change some of the sequence, it is a much more cautious approach to fully build before painting and will take you a lot longer to finish your build.
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.
SS100 Build Manual (Export Edition) Rev 10 November 2013 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.
SS100 Build Manual (Export Edition) Rev 10 November 2013 70. Tuning and testing. 71. Road preparation. Page 11...
SS100 Build Manual (Export Edition) Rev 10 November 2013 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 DELIVERY DATE ★ Special order SECTION 1...
SS100 Build Manual (Export Edition) Rev 10 November 2013 ★ Special order SECTION 1 CHASSIS BUILD UP Page DESCRIPTION Front top ball joints x2 Front upper wishbone inner mounting shaft x2 Front chrome washers x8 Front upper caster shims x6 Front wheel bearing car set (early or late type)? Front upright s/axle + washer, nut &...
SS100 Build Manual (Export Edition) Rev 10 November 2013 DATE LOCATION CUSTOMER NAME BUILD No. DELIVERY DATE ★ Special order SECTION 1a ENGINE GEARBOX Page 3 DESCRIPTION Jaguar XJ6 engine:- Donor or Remanufactured by 3.4 3.8 4.2 ______________ Engine mountings, SS made steel units, x 2 Engine mounting rubbers, x 2 Alternator 18 ACR, donor unit,/ rebuilt unit.
SS100 Build Manual (Export Edition) Rev 10 November 2013 DATE LOCATION CUSTOMER NAME BUILD DELIVERY DATE ★ Special order SECTION 2 BODY & FITTINGS Page 4 DESCRIPTION ★ Wing rivets? Bodywork, in GRP, chassis fitted with doors hung RHD or ★ LHD Valance made in GRP or ★...
SS100 Build Manual (Export Edition) Rev 10 November 2013 ★ Special order SECTION 2 BODY & FITTINGS Page 5 DESCRIPTION Seat frames with bases and backs – metels black painted x 2. Seat foams, x 2. Door check strap holders - chromed x 4 Rear compartment locks x 2 Floorboard set including angle brackets &...
SS100 Build Manual (Export Edition) Rev 10 November 2013 DATE LOCATION CUSTOMER NAME BUILD No. DELIVERY DATE ★ Special order SECTION 3 FINISHING COMPONENTS Page 6 DESCRIPTION Windscreen, SS folding, glazed, chromed. Windscreen fitting kit Aeroscreens x 2 with fixings...
• 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.
5/8” reamer. Please contact Suffolk Sportscars who may be able to supply one on loan if you need one. Page 19...
SS100 Build Manual (Export Edition) Rev 10 November 2013 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.
Important Note: The front suspension of some older donor cars differs from others and a number of parts are not interchangeable. Both types can be fitted to the standard Suffolk chassis and Suffolk will supply reconditioned parts, which are compatible. To identify which you have, examine the lower & upper wishbones.
Its not unknown for the nyloc nut at the bottom to need to be shortened slightly as it’s a tight fit between the wishbone, this is best done on a lathe, Suffolk Sportscars can send thinner nuts if required.
Basic setting of the tracking If you have either donor car wheels or the SS100 hubs and wheels you can set up the front wheel alignment approximately with the engine out as follows. Mount the two front wheels on the hubs. By screwing the track rods in or out set the wheels straight ahead by eye.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Braking system & clutch hydraulics. You will need the following parts for this operation: Foot pedals & cross shaft. • Brake master cylinder, servo unit and clevis/split pin. • 8mm ID x 12mm spacers – supplied with servo (4).
1/2” self tapping screws using the 3 holes drilled before fitting the steering rack (This pipe may have been shaped for you by Suffolk Sportscars). Do the same with the shorter right hand brake pipe (F2) using the top outlet in the four way union. Then connect the rear four way union outlet to the rear most connection on the master cylinder (F3 this may require a banjo bolt)..
The sender float arm should be pre-shaped for you by Suffolk Sportscars, if not adjust the arm so the float is just off the bottom of the tank this should leave the gauge reading empty when it still has a little fuel left for safety.
The installation of an in line filter between the tank and the fuel pump is a wise, added precaution although the pump does have its own filter, Suffolk Sportscars fit a filter under the bonnet before the carbs where it is easier to see and clean when full.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Safety note: The engine and gearbox assembly weighs 350 kg. Ensure that any lifting equipment is adequately rated for this weight. This includes all strops, chains and shackles. 5.1.3 Fitting engine Rig the engine and gearbox assembly to an engine crane using the two lifting eyes attached to the front &...
Oil pressure sensor (if electrical gauge being used) • Water temperature sensor (if electrical gauge being used) • If using Suffolk Sportscars supplied gauges they are mechanical, the two switches above not required. Stop light switch • Cooling fan and control switch •...
SS100 Build Manual (Export Edition) Rev 10 November 2013 5.4.1 Front end wiring loom Start by identifying the front end of the loom for the headlamps and engine and pass this through the servo plate, to locate loom in correct position take the headlamp/horn connections (one or two white plugs for each side) and place them behind and on each side of the chassis cross member that runs below the radiator.
SS100 Build Manual (Export Edition) Rev 10 November 2013 5.4.7 Cooling fan and switch Install the cooling fan switch into the top of the radiator using a copper or aluminum washer to seal. If not already fitted, install cooling fan to front of radiator. Insert supplied rubber bushes between fan and radiator before pushing the special zip ties through the radiator core, fit four more rubber bushes between radiator core and zip tie catch plate.
SS100 Build Manual (Export Edition) Rev 10 November 2013 5.4.12 Fog lamp If required the rear fog lamp can be fitted at this stage as access is better without the body fitted. Fix the fog lamp to the rearmost cross member just inboard of the exhaust pipes on the offside. This can then be connected up, make sure the main loom runs along the top of the chassis to allow enough cable to reach inside each of the main rear lamps.
If using your own donor wheel nuts these may need shortening so they don’t catch on the inside of the wire wheels, contact Suffolk Sportscars if unsure or if you need yours exchanged for ready shortened nuts.
SS100 Build Manual (Export Edition) Rev 10 November 2013 5/16” UNF x 11/2” bolts & nyloc nuts (4) • 5/16” UNF x 2” bolts & nyloc nuts (6) • 3/8” & 5/16” plain washers as needed • 5/16” mudguard washers - as needed •...
SS100 Build Manual (Export Edition) Rev 10 November 2013 7.1.4 Door fitting With the body bolted down with the supplied spacers you must now fit the doors to check that they fit and an even gap is obtained at the front and rear of the doors. If this fit is not satisfactory mark or measure shims at positions B &...
M4 x 10mm chrome headed (or polished SS) domed countersunk screws & nyloc nuts (16) • 3mm alloy pop rivets – for temporary use (16) • Cutting and preparing your own bonnet is an option, Suffolk Sportscars will be happy to cut and prepare your bonnet if required. 7.2.1 Bonnet details The bonnet is handmade in 4 louvered aluminium panels, two top panels and two side.
Drill 6 holes to accept 3mm rivets, 3 in each U section, 2 pairs 15 mm from each end and one pair in the centre. These holes must also be deburred as above. Suffolk Sportscars usually does this for you. 7.2.5 Positioning top hinge To find the centre of the bulkhead, locate a length of flexible wire or string and use the following method.
SS100 Build Manual (Export Edition) Rev 10 November 2013 edge. Lift both panels to the upright position and check that the louvres on both panels align with each other, adjust if needed and lower back down before checking the rear edge of both panels still cover the shut line.
SS100 Build Manual (Export Edition) Rev 10 November 2013 achieve this) now drill a 3mm hole through the panel in the predrilled hinge hole. Temporally attach the bottom panels with M3 nuts and bolts. Fit the four ripaults on the bottom panels using M4 screws and nuts and refit bonnet to the car.
The brackets in turn can be bolted to the timbers. The body shell can then easily be transported on an average size trailer. Most of the original SS100’s had the interior surfaces of the bonnet painted. • Note: While the body is away for painting is a good time to fill the engine and gearbox with oil. Refer to Appendix 4 for the correct lubricants.
SS100 Build Manual (Export Edition) Rev 10 November 2013 fixing screw. 7.3.5 Safe storage After you have all your body fixings, the doors and bonnet in place and are happy with there positions it can be safer to remove them and store them safely until you are finished with under bonnet connections or you are ready to trim the interior.
SS100 Build Manual (Export Edition) Rev 10 November 2013 8.1.4 Rear floorboard upright mount Check the rear end of the floorboards are parallel with each other and roughly level with the metal cross tube above, then offer into place the two alloy angle sections (one side is longer then other as differential is offset).
5 or 6 clicks. 8.1.10 Gearbox cover The standard gearbox cover supplied by Suffolk Sportscars is for the compact four gearbox with overdrive, other types are available please phone to advise of your spec. Referring to Fig 22 prepare your gearbox cover by drilling holes for access to starter motor bolts, gearbox switches and speedometer cable (optional could reach through bulkhead).
SS100 Build Manual (Export Edition) Rev 10 November 2013 1no. Length of Sticky backed Sponge Rubber • 2no. aluminium load spreading plates • Note: To fit the screen the builder will need the help of a second person. Before starting ensure that the car is level, particularly transversely.
These are used for the tonneau and the side screens. All these studs may already be fitted by Suffolk Sportscars. 8.2.9 Aero screens Finally check the fit of the aero screens on their spindles, they should side on and off easily, if not try loosening the spindle mounts before fitted the aero screens then re-tightening the screws.
Next by finger from behind the valance screw down the adjustable spacer nut to meet the chassis before fitting the lock washer and nut from underneath. Make sure that the lamp bar fits satisfactorily, if not talk to Suffolk Sportscars about adjusting the aluminium spacers as necessary. 8.3.3...
The choke cable can be mounted in its own plate if preferred or in the mounting “Z” bracket that can be supplied by Suffolk Sportscars for fitting and auxiliary switches or sockets. This switch panel is mounted behind the wiper strap using the same bolts and sticks out under the wiper motor. Run the cable without any sharp kinks through any hole in the bulkhead that suits the root needed to reach your chosen type of carburetors and connect it to the linkage testing that it pulls in and out without jamming.
SS100 Build Manual (Export Edition) Rev 10 November 2013 8.3.10 Rear lamp brackets Test fit the rear lamp brackets to check the fit is level, remove the brackets and cut a rubber gasket to suit, this is best cut undersize as they will squash out when fitted. Stamp the three mount holes and a central hole for the rear lamp wiring.
SS100 Build Manual (Export Edition) Rev 10 November 2013 8.3.18 Running board strakes Refer to figure 12 to assist in fitting your running board strakes. The looks of the running board strakes are much improved by gently curving the strakes to go with the body shape, both upwards as they go forward to match the running board curve and inwards to match the body shape, they will need curving to various degrees starting straight for the outer strake to curved to match the body line on the inner strake.
On the left side of the dashboard is space to fit the dummy fuel tank switch, this is to replicate the original SS100. Protect the dashboard with masking tape, offer up the switch and mark the top and bottom mount holes, remove the switch and drill holes to suit.
SS100 Build Manual (Export Edition) Rev 10 November 2013 all pedal movement. The fuse box can also be positioned and screwed through the bulkhead. 9.1.4 Main earth The loom then needs to go over the column and follow the large roll hoop behind the dashboard, locate the eyelet with multiple black earth cables and attach this to the left hand bolt which holds the wiper motor “Z”...
The next four wires are for an optional hazard-warning switch, there are generally two types of connections for these. The majority of these switches, like the one supplied by Suffolk Sportscars will use the top four wires below but some will need to intercept the input to the stalk for the flashers. The switch can be mounted in its own plate if supplied or in the mounting “Z”...
9.1.14 Water temperature gauge Next fit the water temperature gauge, if using electric gauge extend wires to reach wires in section 12 above, if using Suffolk Sportscars supplied mechanical gauge the capillary tube needs to be fed through the dashboard...
PTFE tape on all threads to help sealing. Note: the adaptor is slightly different at each end and needs to be fitted correctly, if unsure please talk to Suffolk Sportscars before fitting as thread can be damaged by fitting incorrectly. 9.1.15 Instrument illumination...
SS100 pull switches, options are: 1) Choose which speed suits you best and only connect that wire. 2) Use a two-speed dash switch, at present no new switches are available to match the SS100 pull switches.
+12v to spotlamp/s 9.1.25 Oil pressure gauge If using an electric gauge extend wires to reach wires in section 12 above, if using Suffolk Sportscars supplied mechanical gauge the capillary tube needs to be fed through the dashboard hole, across the roll hoop and through the bulkhead to the engine, make sure the tube is not kinked or able to jam in any moving parts.
Front lamps, horns and alternator There are two types of headlamps available from Suffolk Sportscars, these are the “Type 40” and QK596. The Type 40 are smaller stainless steel items whereas the QK596 are chrome on brass and are identical to the original SS100 headlamps.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Headlamp bulb, looking toward terminals Loom wires Power Left terminal Black -12v Chassis earth Top terminal Blue/Red or Blue/Orange +12v Dipped beam from stalk Right terminal Blue/White +12v Main beam from stalk Side lamp Red/White –...
SS100 Build Manual (Export Edition) Rev 10 November 2013 Headlamp bulb Loom wires Power Body earth Black -12v Chassis earth wire, may need swapping with below Blue/Red or Blue/Orange +12v Dipped beam from stalk wire, may need swapping with above...
If not already been done by Suffolk Sportscars, glue some insulating material (e.g. rubber, cloth tape) to the inside top of the lamp case as there is very little room inside these lamps the wires are very close to the outside case.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Right hand lamp. Brake/side lamp Loom wires Power 21 watt terminal Green/Purple +12v from brake lamp switch 5 Watt terminal Red/White, & link to side lamp below +12v from fuse box...
SS100 Build Manual (Export Edition) Rev 10 November 2013 9.2.11 Testing All electrics should now work and can be tested as below: Side, headlamp dip/main/flash and panel lights • Spot lamp/s (if fitted) • Brake lights* • Ignition warning light* •...
SS100 Build Manual (Export Edition) Rev 10 November 2013 Final Body Fittings You will need the following parts for this operation: Steering wheel & boss. • Number plates • Chassis plate • GB plate • Luggage rack (optional) • Seat belts including all brackets and fastenings.
SS100 Build Manual (Export Edition) Rev 10 November 2013 12.5 Seat belts The seat belts can now be fitted using the brackets and fastenings supplied, You will find a long tube adaptor for the lower mount and a top hat adaptor for the upper mount, the upper mount needs to be able to swivel so if its too tight remove and add a spacer washer behind the spacer.
SS100 Build Manual (Export Edition) Rev 10 November 2013 13.2 Carburetion 13.2.1 Carburettor base settings Remove the carburettor dashpots by first removing the screw top dampers (lay these down somewhere clean) then remove the four screws around the dashpots and lift them away along with the dashpot springs below.
SS100 Build Manual (Export Edition) Rev 10 November 2013 carburettor linkage making sure if there is any slack you take this up as both carburettors need to open at exactly the same time. 13.2.7 Setting mixtures The mixtures are best set on a gas analyser but you can set them close by following these instructions. If possible make sure you have the correct needles for your set up.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Your running in period is now complete and your service intervals are as per the factory instruction for your model. Note: When tightening the nuts for the polished cam covers, do not overtighten, use 4 ft-lb torque max.
Appendix 6 for instructions on doing this. 14.8 Servicing. Your car will need regular servicing, please refer to section 13 for service intervals. There is a Suffolk Sportscars service sheet in this manual to help guide you to what needs doing, see appendix 5.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Appendix 1: Electrical Systems Wiring Loom Positions Key (Refer to Appendix 2 Fig 31) A.Gearbox section Green Overdrive inhibitor switch Ignition supply Yellow/Blue Switched feed out Grey/red Automatic gear selector switch...
SS100 Build Manual (Export Edition) Rev 10 November 2013 D. Dash section (continued) Black Earth feed Purple Hazard lamp switch, MOT requirement if donor car Live feed, connect to flasher Green/white fitted with one otherwise optional Fight indicator feed Green/red...
SS100 Build Manual (Export Edition) Rev 10 November 2013 Appendix 1.1 Fuses and relays. Fuses Bulkhead mounted fuse box, this could be mounted either way up. Right hand front and rear side lamps and dashboard illumination (22). 3 Amp Left hand front and rear side lamps (23).
SS100 Build Manual (Export Edition) Rev 10 November 2013 Figure 3 – Exhaust system assembly Page 79...
SS100 Build Manual (Export Edition) Rev 10 November 2013 Figure 4 – Front Wishbone Identification. Late XJ6 Lower Wishbones Early XJ6 Lower Wishbones Most common type. Straight outer end, spacer in Curved outer end that points front of chassis, special...
SS100 Build Manual (Export Edition) Rev 10 November 2013 Figure 5 – Peering of the bonnet panel edges Figure 6 – Carburettor Pipe Location Below is the most common carburettor type. If your carburettors are different please refer to Haynes Manual or contact Suffolk Sportscars.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Figure 7 – Seat Runner Positions Initial drilling for right hand inner seat runner before floorboards fitted, mirror image for left hand inner runner. A (seat belt clip mount) to B variable depending on height of driver 150mm – 190mm.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Figure 8 – Jig tool for marking out lower body fixing holes Figure 9 – Location of throttle pedal Page 83...
SS100 Build Manual (Export Edition) Rev 10 November 2013 Figure 10 – Location of door latches Figure 11 – Location of rear reflectors Page 84...
SS100 Build Manual (Export Edition) Rev 10 November 2013 Figure 13 – Strake Fitting Positions for strakes: Rear end of strakes level and 83 mm forward of rear edge of door. • First strake fitting - A 25 mm from edge of body.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Figure 15 – Floorboard Fitting Kit A & B 2no. M6 x 20mm countersunk slot screws – drill 5mm hole & tap M6 C1 & D1 2no. M6 x 20mm countersunk slot screws – drill 5mm hole & tap M6 C2 &...
SS100 Build Manual (Export Edition) Rev 10 November 2013 Figure 16 – Headlamp alignment Figure 17 – Body to Chassis Fixing Locations Positions B,C,D and E are the main horizontal mounting points (spacers supplied if needed) G,H,J and K are bonnet hook mounting points (spacers supplied if needed) A and F horizontal mounts and vertical positions which are marked with stars will need spacers made keeping body in its natural position.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Figure 20 – Drilling hole of bonnet hinges for rivets Headlamp bar fixings positions a – ‘O’ rings, slide over bar before fitting. b – Rubber washers Super glue to hold in place to protect body.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Figure 22 – Cut out holes in gearbox cover for maintenance Figure 23 – Shock absorber height adjustment Page 92...
Figure 24 – Wiring of rear lamps It is optional which way around you mount your rear lamps i.e. red outside or inside. Suffolk Sportscars suggest the way below as this means the tail lamp also known as the marker lamp is towards the outer edge of the body marking the outer most position of the body.
Fluid Levels Engine (8.25 Litres of Mineral 20w/50) – If you have received a newly reconditioned engine from Suffolk Sportscars, it is important to follow to procedure below: The engine will have been test run at the engine builders. They use a running in oil, which is usually drained prior to delivery due to courier regulations.
SS100 Build Manual (Export Edition) Rev 10 November 2013 An engine oil change with new filter requires 8.25 litres of oil. Proceed by measuring as accurately as possible (using a measuring jug) the correct amount. When the oil has settled and drained back into the sump, the dipstick can be checked for accuracy taking into account the capacity of the filter.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Appendix 5 - Suffolk Sportscars ANNUAL SERVICE (or every 3000 miles) OWNER/CAR: REG. NO: MILEAGE: UNDER BONNET CHECKS: check/clean inline fuel filter check/clean/replace air filters check brake fluid level under bonnet ...
SS100 Build Manual (Export Edition) Rev 10 November 2013 check seat & belt operation anchorage points check / tune carbs gas test DEALER SERVICE STAMP: check condition of all weather gear & windwings (inc. studs) check tool kit, hammer, jack ...
COMPLETELY FALSE RESULTS * When you have completed the calibration information sheet, send it and your gauge to the address below with a cover letter stating that you have built your own Suffolk SS100 and you require an express return service.
SS100 Build Manual (Export Edition) Rev 10 November 2013 Appendix 10 – Customer Order Form Suffolk Sportscars Ltd ORDER BY POST OR FAX POBox 100, Woodbridge, Suffolk IP12 9BA. Tel & Fax 01728 745000 CUSTOMER DATE OF NAME ORDER Please order for me the following items. My order number is BUILD MANUAL BUILD SECT.