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Introduction; Tools, Equipment & Ordering Of Parts; Tools Required; Fasteners - Suffolk SS100 Build Manual

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SS100 Build Manual (Export Edition)


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. 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
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

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.


Suffolk Sportscars can supply all nuts, bolts and fasteners in a comprehensive 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
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Rev 10 November 2013