Steering; Fitting Brake Caliper, Steering Arm And Disc Protector; Pre-Drill Brake Line Hose Clips; Steering Rack - Suffolk SS100 Build Manual

SS100 Build Manual (Export Edition)
4.2.13 Test fit brake caliper and steering arm
Assemble the steering arm and the brake caliper in position using the three dedicated bolts. Ensure that the
bleed nipple is at the top of the caliper. It is possible to assemble them upside down! The upper part of the
disc protector can be left out at this stage. Tighten the bolts to fully locate the caliper but do not torque at this
stage. Now measure the gaps between the abutments above and below the brake pad locations and the inner
and outer edge of the brake disc. The brake caliper should be roughly central at both upper and lower
position, fit shims or washers between the caliper and the stub axle carrier at the upper and lower mounting
positions if necessary to achieve this.

4.2.14 Fitting brake caliper, steering arm and disc protector

Now reassemble the steering arm, upper part of the disc protector and brake caliper and torque the three bolts
to 55ft-lbs. Using the 0.8mm S/S wire lock together the two caliper securing bolts by passing the wire
through cross drilled hole in the top bolt before twisting the wire then pass it through the bottom bolt before
finishing with a final twist (special pliers are available to do this).
4.3

Steering

You will need the following parts for this operation:
Steering rack from donor car modified by Suffolk, complete with track rods.
•
Note Both metric (M14x1.5)and imperial (5/8" UNF) track rods were used, make sure you get the
correct track rod ends.
3 special polyurethane rack mounting bushes and 6 large washers.
•
5/16"UNF x 21/2" bolts (3).
•
5/16"UNF nyloc nuts (3).
•
Track rod ends, either 5/8"UNF or M14 fine (1.5mm pitch) depending on rack (2).
•
Track rod lock nuts, either 5/8"UNF or M14 fine (2).
•
4.3.1

Pre-drill brake line hose clips

Drill the three holes on the underside of the front cross member for the P clips to support the brake line to the
front nearside caliper and wiring loom to left hand lamps and alternator before mounting the steering rack
(see next section). Access afterwards is difficult, this should already be done by Suffolk Sportscars.
4.3.2

Steering rack

Attach the steering rack to the chassis using the 3 polyurethane bushes, washers, bolts and nuts. The centre
tubes of the bushes need to sit into the centre of the washers otherwise the bushes will not tighten fully.
Tighten to 18ft-lbs.
4.3.3 Track rod ends
Set the steering rack to its central position. Screw the track rod end lock nuts and track rod ends on
to the track rods and position them such that when fitted to the steering arms and the hubs in the straight
ahead position, the effective length of each track rod is the same. Tighten the track rod end to steering arm
nuts to 45ft-lbs.
4.3.4 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. Find a suitable piece of wood and cut to length so that it
will slide between the inner faces of the wheel rims or tyres when positioned transversely across the chassis.
Adjust the track rods so that the rear gap is 1/16" greater than the rear giving 1/16" toe in. Tighten the track
rod lock nuts. Alignment should be checked and reset as necessary at a garage with optical alignment
equipment at a convenient time before road running the car.
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Rev 10 November 2013