8.1.9 Handbrake lever
The handbrake lever can now be fully fitted with its brackets and connected up to the handbrake cable. Bolt
the rear handbrake mount through the floorboard, prop-shaft hoop and cable retaining bracket using the
supplied bolts. The front handbrake mount has a ‘S’ bracket which mounts under the floor between the
handbrake mount and the chassis and is secured with the supplied 5/16 unf bolts. You can then connect up
the handbrake cable, the outer cable needs two nuts fitted, one either side of the cable retaining bracket, the
inner cable attaches to the handbrake pivot fitting again with a nut on either side. Use these nuts to adjust the
cable so that the handbrake comes up ideally 5 or 6 clicks.
8.1.10 Gearbox cover
The standard gearbox cover supplied by Suffolk Sportscars is for the compact four gearbox with overdrive,
other types are available please phone to advise of your spec. Referring to Fig 22 prepare your gearbox cover
by drilling holes for access to starter motor bolts, gearbox switches and speedometer cable (optional could
reach through bulkhead). Also cut the hole to accept the gear stick, don’t cut this too big, trial fit the
gearbox cover to find position and size of hole required. You may need to do this a few times, make sure the
cover fits as far forward as possible, you may need to cut two slots in the tunnel to accept the strengthening
ribs on the gearbox top.
When ready to fit the gearbox and prop-shaft cover, draft excluder fitted to the forward face of the gearbox
cover will act as a seal between the engine and passenger compartment. Spread the rear edges of the gearbox
cover and tunnel mouldings to give good clearance for the prop shaft flanges (remember that the gearbox
will move sideways when cornering against its rubber mount). This is easier with the help of a second person
underneath the car using a bar as a lever. When satisfactory secure them both by drilling and fitting 5/8” No
6 countersunk head woodscrews. Fit the gear knob to the gearlever (this will have to be removed for
trimming but safer to have it fitted now as gear sticks can be sharp).
8.1.11 Alloy chassis cover plates
The last parts to fit to the floorboards are the two alloy cover plates that fill in the rear corners at the back of
the main floorboards, mark the and drill positions for the seat belt mounts before fitting these in place with
screws.
8.1.12 Sealing floorboards
The floorboards can now be sealed in with flashband (self adhesive flashing tape available from builders
merchants) all round the edges and down the sides of the gearbox cover, the access holes can also be
covered. The front of the right hand side will need a bridging plate made from alloy or wood before covering
with flashband.
8.2 Windscreen and wipers
You will need the following parts for this operation:
• Windscreen assembly
• Windscreen sealing rubber
• Windscreen wiper motor and “U” bracket
• Windscreen wiper rack, wheelboxes complete with 4 fixing nuts (7/16”UNF)
• Wiper arms and blades
• Side mirrors (2) plus 2BA screws (4)
• Windwings (2) (Optional)
• Aeroscreens (2), fitting brackets (4) & screws (8)
• 8no. Tenex Studs + spring washers (usually fitted to screen)
• 6no. M6x30mm Stainless Steel Fixing Screws + nuts & washers
• 1no. Length of Flat Rubber (enough to make 4no. gaskets)
• 1no. Length of ‘U’ Section Rubber Extrusion (rear side) & 1no. Length of ‘Y’ Section Rubber
Extrusion (front side)
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