Suffolk SS100 - Trimming

114 pages

Save Page as PDF

To Next Page

To Next Page

To Previous Page

To Previous Page

Loading...

SS100 Build Manual (Export Edition) Rev 10 November 2013

Page 65

11 Trimming

Section to follow.

Table of Contents

Table of Contents3
Index3
Tools, Equipment & Ordering of Parts6
Tools Required6
Fasteners6
Introduction6
Ordering of Parts7
Parts Delivery Disclaimer7
Build Sequence & Parts List8
3.2 Parts List12
Chassis, Suspension, Steering & Final Drive18
Rear Suspension and Final Drive18
- Fitting Bushes19
- Differential Mounting Plate19
- Rear Axle Set up19
- Installing Axle19
- Handbrake Return Springs20
Front Suspension20
- Rear Tie Bars20
- Coil over Damper Mounting with Spacer20
- Upper Wishbone Pivot Shaft21
- Upper Wishbone Bushes21
- Upper Ball Joint21
- Lower Wishbone Pivot Shaft21
- Lower Wishbone Bushes22
- Hub and Brake Disc22
- Fitting the Hub22
- Coil over Dampers22
Steering23
- Fitting Brake Caliper, Steering Arm and Disc Protector23
- Pre-Drill Brake Line Hose Clips23
- Steering Rack23
- Clutch Master Cylinder24
- Pedals24
- Brake Master Cylinder and Servo24
Braking System & Clutch Hydraulics24
- Rear Brake Line25
- Rear Brake Link Pipes25
- Front Brake Lines25
- Brake Lamp Switch25
Fuel Tank, Fuel Pump and Fuel Line26
- Setting Tank Fuel Sender26
- Fitting Tank Fuel Sender26
- Fuel Tank and Straps26
Engine, Gearbox, Exhaust System, Cooling System & Initial Wiring27
Engine, Gearbox & Prop-Shaft27
- Engine Brackets and Timing Pointer27
- Gearbox Mount Plate, Rubber Mount and Adaptor27
Exhaust System28
- Servo Vacuum Hose28
- Connect and Bleed Clutch28
- Clutch Slave Cylinder28
- Fitting Engine28
Cooling System29
- Down Pipes or Stainless Manifold Extension Pipes29
- Silencers29
- Rear Tie Bracket29
Initial Wiring30
- Radiator Lower Mounts30
- Bottom Hose30
- Radiator Top Mounts30
- Front End Wiring Loom31
- Rear and Gearbox Loom31
- Coil31
- Electric Oil Gauge Sender31
- Overdrive Inhibit Switch32
- Fuel Pump32
- Overdrive Solenoid32
- Cooling Fan and Switch32
- Fog Lamp33
- Reverse Lamp33
- Brake Fluid Reservoir Wires33
- Starter Moto33
Wheels & Tyres34
Splined Hubs34
Fitting Wheels34
Body, Doors and Bonnet Fitting34
7.1 Body34
Preparing Wheels34
- Lifting on the Body35
- Bolting on the Bod35
- Body Tightening Sequence35
- Dashboard Stays36
Bonnet36
- Final Body Mount Bolts and Spacers36
- Windscreen Wiper/Scuttle Bracket36
- Door Fitting36
- Bonnet Details37
- Bonnet Fitting/Cutting Advice37
- Preparing Centre Hinge37
- Preparing Outer Hinges38
- Positioning Top Hinge38
- Radiator Hoop and Long Stays38
- Radiator Shell38
- Securing Top Bonnet Panel39
- Marking the Bonnet Panels39
- Cutting the Top Bonnet Panels39
- Fitting Side Hinges39
7.3 Painting40
- Fitting Bonnet Studs40
- Cutting Bottom Panels40
- Bottom Bonnet Beaded Edge40
- Refitting Body41
- Refitting Doors41
- Refitting Painted Bonnet41
Body Fittings42
Safe Storage42
Floorboards, Handbrake and Seat Runners42
- Handbrake Cable42
- Rear Floorboard Upright Mount43
- Rear Floorboard43
- Rear Brake Access Panel and Tool Tray43
- Handbrake Lever43
Windscreen and Wipers44
- Gearbox Cover44
- Sealing Floorboards44
- Wiper Spindle Holes45
- Mirror and Aero Screen Brackets45
- Fixing Windscreen45
- Windscreen Positioning45
Remaining Body Fittings46
- Tenax and Lift the Dot Studs46
- Aero Screens46
- Wiper Arms and Blades46
- Front Valance and Dummy Starting Handle Eye47
- Fitting the Lamp Bar47
- Lamp Bar Stays47
- Wing Stays47
- Upper Steering Column48
- Lower Steering Column and Escutcheon48
- Throttle Pedal48
- Choke Cable48
- Fuel Cap, Adaptor and Link Pipe49
- Rear Reflectors49
- Spare Wheel Bracket49
- Rear Lamp Brackets49
- Running Board Strakes50
Dashboard Fittings51
- Grab Handle51
- Fuel Switch (Dummy)51
Wiring and Electrical Fittings51
- Main Earth52
- Main Power Feed52
- Stalk Switch52
- Relay Earths52
- Steering Column Ignition Key53
- Hazard Warning Lamps53
- Heater53
- Electrical Instruments and Automatic Gearbox Illumination54
- Low Charge Warning54
- Main Wiring Earth54
- Wiper Motor54
- Instrument Illumination55
- Ammeter55
- Headlamp Switch55
- Fuel Gauge56
- Windscreen Wiper Switch56
- Starter Push Button56
- Dashboard Ignition Key56
- Overdrive Switch57
- Tachometer57
- Spot Lamp Feed57
- Oil Pressure Gauge57
Front Lamps, Horns and Alternator58
- Speedometer58
- Headlamps Type 40 and Horns58
- Headlamps QK596 and Horns59
- Flasher Lamps60
- Spot Lamps60
- Rear Lamps61
- Side Lamps Combined with Flasher Lamps61
- Alternator61
- Right Hand Lamp62
- Left Hand Rear Lamp62
- Fuel Gauge Sender62
- Earth Feed62
- Testing63
- Wiper Blade Fitting63
Interior Trimming64
Trimming65
Final Body Fittings66
Steering Wheel and Boss66
Front Number Plate66
Rear Number Plate and GB Plate66
Luggage Rack66
- Ignition Settings67
- Ignition Setting, Carburetion, Testing Running and Tuning67
- Chassis Plate67
- Seat Belts67
- Carburetion68
- Carburettor Base Settings68
- Warm up68
- Dwell Angle68
- Setting Mixtures69
- Engine Checks69
- Test Running and Tuning69
- Driving and Service69
- Road Preparation70
- Wheel Alignment70
- Suspension Setting70
- Headlamp Alignment70
- Servicing71
- Tyre Pressures & Greasing Points71
- Speedometer Calibration71
- Electrical Systems72
- Wiring Loom Positions Key72
- Fuses74
- Line Fuses74
- Relay Fuses74
- Relays74
- Wiring Diagram75
- Key to Circuit Diagram75
- Wire Colour Coding75
- Optional Items75
- Figures77
- Puller for Differential Mounting Bushes78
- Setting Rear Wheel Camber78
- Exhaust System Assembly79
- Early XJ6 Upper Wishbones80
- Early XJ6 Lower Wishbones80
- Late XJ6 Lower Wishbones80
- Front Wishbone Identification80
- Peering of the Bonnet Panel Edges81
- Carburettor Pipe Location81
- Seat Runner Positions82
- Jig Tool for Marking out Lower Body Fixing Holes83
- Location of Throttle Pedal83
- Location of Door Latches84
- Location of Rear Reflectors84
- Strake Fitting85
- Cutting and Gluing Rubber Insert85
- Dashboard Layout and Grab Handle Location86
- Windscreen Fitting86
- Floorboard Fitting Kit87
- Picture to Left87
- Body to Chassis Fixing Locations88
- Heater Fitting Instructions89
- Heater Kit Contents89
- Loom Placement Diagram90
- Drilling Hole of Bonnet Hinges for Rivets91
- Headlamp Bar Fixings Positions91
- Steering Column Locating Jig91
- Cut out Holes in Gearbox Cover for Maintenance92
- Shock Absorber Height Adjustment92
- Wiring of Rear Lamps93
- Photographs94
- Rear Axle Components94
- Assembled Engine, Gearbox and Rear Axle94
- Rear Axle Fitted95
- Early Build Stages96
- Rolling Chassis96
- Stainless Steel Manifolds Fitted97
- Lucas Qk596 Headlamps98
- Different Headlamp Options98
- Type 40 Headlamps98
- Fluids, Lubricants and Maintenance Data99
- Tyre Pressures99
- Wire Wheels99
- Adjustable Shock Absorbers99
- Running in and Service Instructions100
- 500 Miles100
- 500 - 1000 Miles100
- 1500 Miles100
- Suffolk Sportscars ANNUAL SERVICE101
- Speedo Calibration103
- RHD Brake Pipe Locations104
- Suffolk SS100 Dimensions105
- Suffolk SS100 Chassis Details106