1 Introduction
The scope of this manual is to provide all the information necessary to build the Suffolk C-type replica.
It assumes that all donor car parts are supplied by Suffolk Sportscars, fully refurbished and built into
subunits where necessary, ready for assembly along with all other parts required for completion of the car. If
a builder wishes to refurbish donor parts himself he should contact Suffolk Sportscars for advice first.
2 Garage and Tools
A single sixteen by eight foot garage is sufficient space to build the Suffolk C-type, but more room is useful.
You will need a small workbench and a vice.
2.1 Principal Tools Required
• Spanners - combination sets covering 3/8” - 1” AF and 10 – 26 mm
• Sockets sets – 1/2 inch drive covering 3/8” - 1” AF and 10 – 26mm
• Torque wrench – 1/2-inch drive of 100-ft/lb capacity
• Mains and/or battery drill with 1/2 inch/13mm chuck
• Drill bits – 1 – 13mm in 0.5mm steps
• Taper taps – various sizes, imperial and metric
• Allen keys - imperial and metric sets
• Selection of basic hand tools - screwdrivers, pliers, files and hacksaws etc
• Electrical test meter
• Side cutters and crimping pliers
• Sheet metal cutters for adjusting aluminium panels
• Nutsert set with selection of sizes
• Four axle stands - rated at one tonne each
• Trolley jack – a basic one will do but a two tonne model giving a fifteen-inch lift is well worth the
money
• Engine crane – capable of lifting up to one tonne. If you don’t wish to purchase one or have no place
to store one it is easy to hire an engine crane for a couple of days from a number of hire companies
3 Fasteners
Suffolk Sportscars can supply all nuts, bolts, washers and fasteners. This package comes as a complete and
comprehensive kit that gives descriptions, sizes and locations for chassis and body build.
Most Jaguar components use unified (imperial) threads, mostly UNF (fine thread) but UNC (coarse thread)
is also used for threads in aluminium. Exceptions are steering racks on some later cars where the track rod
ends are threaded. M14 fine (1.5mm pitch) and later brake master cylinders use metric threads. SU
carburettors use BSF and BA. Fuel tank senders are 2BA and Weber carburettors use metric.
It is recommended that stainless steel fastenings be used for fittings to the body and for those directly
exposed to road dirt and salt. Stainless fasteners in unified threads are difficult to obtain but metric ones are
readily available and are used for this reason wherever possible. It is also recommended that all non stainless
steel fasteners are high tensile bright zinc plated (BZP).
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