Index; Table Of Contents - Suffolk SS100 Build Manual

SS100 Build Manual (Export Edition)
Build Manual for Suffolk SS100 Sports Car
1. Introduction . ........................................................................................................................ 6
2. Tools, e quipment & o rdering o f p arts . .................................................................................. 6
2.1 Tools R equired ....................................................................................................................................................................... 6
2.2 F asteners . ................................................................................................................................................................................ 6
2.3 Ordering o f p arts ................................................................................................................................................................... 7
3. Build s equence & P arts l ist . .................................................................................................. 8
3.1 Build s equence A ................................................................................................................................................................... 8
3.2 P arts L ist . ................................................................................................................................................................................... 1 2
4. Chassis, s uspension, s teering & f inal d rive . ......................................................................... 1 8
4.1 Rear s uspension a nd f inal d rive . ................................................................................................................................. 1 8
4.2 Front s uspension. . ............................................................................................................................................................. 2 0
4.3 Steering . ................................................................................................................................................................................. 2 3
4.4 Braking s ystem & c lutch h ydraulics. . ........................................................................................................................ 2 4
4.5 Fuel t ank, f uel p ump a nd f uel l ine . ............................................................................................................................. 2 6
5 Engine, g earbox, e xhaust s ystem, c ooling s ystem & i nitial w iring . ....................................... 2
5.1 Engine, g earbox & p rop-­‐shaft ....................................................................................................................................... 2 7
5.2 Exhaust s ystem . .................................................................................................................................................................. 2 8
5.3 Cooling s ystem . ................................................................................................................................................................... 2 9
5.4 Initial w iring . ....................................................................................................................................................................... 3 0
6 Wheels & t yres . ................................................................................................................... 3
6.1 Splined h ubs ......................................................................................................................................................................... 3 4
6.2 Preparing w heels . .............................................................................................................................................................. 3 4
6.3 Fitting w heels . ..................................................................................................................................................................... 3 4
7 Body, d oors a nd b onnet f itting . ........................................................................................... 3
7.1 B ody . ............................................................................................................................................................................................ 3 4
7.2 Bonnet . ................................................................................................................................................................................... 3 6
7.3 P ainting . ..................................................................................................................................................................................... 4 0
8 Body f ittings. . ...................................................................................................................... 4
8.1 Floorboards, h andbrake a nd s eat r unners . ............................................................................................................ 4 2
8.2 Windscreen a nd w ipers . ................................................................................................................................................ 4 4
8.3 Remaining B ody F ittings . ............................................................................................................................................... 4 6
9 Wiring a nd E lectrical F ittings . .............................................................................................. 5
9.1 Dashboard F ittings. ........................................................................................................................................................... 5 1
9.2 Front l amps, h orns a nd a lternator . ............................................................................................................................ 5 8
10 Interior T rimming . ............................................................................................................. 6
11 Trimming . .......................................................................................................................... 6
12 Final B ody F ittings . ............................................................................................................ 6
12.1 Steering w heel a nd b oss . ............................................................................................................................................. 6 6
12.2 Front n umber p late . ....................................................................................................................................................... 6 6
12.3 Rear n umber p late a nd G B p late . ............................................................................................................................. 6 6
12.4 Luggage r ack . .................................................................................................................................................................... 6 6

Index

Page 3
Rev 10 November 2013
Page
7
4
4
2
1
4
5
6