Build Sequence & Parts List - Suffolk SS100 Build Manual

SS100 Build Manual (Export Edition)
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 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.
In our experience very few customers damage their cars paint as long you take sensible precautions and always protect
the paint where possible or where there is a risk of damage.
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.
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Rev 10 November 2013