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Construction and Building Procedures

Customer Build Manual 90 pages; fully explains all assembly procedures.
Bound copy: £20.00 refundable against chassis purchase. Price includes 110 picture CD Rom

The customer self-build programme can be modified to suit your individual requirements. The following is a typical short guide to the assembly procedures:

Chassis to be sited on 4 axle stands in a garage or workshop
Fit into chassis the 4 special Metalastic bushes that carry the top and bottom differential mounting plates and secure with Loctite.
Fit into chassis (using the special Suffolk differential mounting plates) the sub-assembly unit of rear driveshafts; lower arms; outer hubs; inboard disc brakes; differential unit (note: This unit can be completely built by Suffolk prior to delivery of the chassis enabling the customer to fit 'the back end' as a single operation).
Fit the 2 rear tie bars with their special bushes and rose joints
Fit the 4 spring coils over the shock absorber units of the rear suspension
Build up the front end of the chassis using the upper and lower suspension wishbones; uprights; Lockheed brake discs; bearings; hubs
Fit 2 spring coils over the shock absorbers and install
Fit front brake calipers to the uprights
Fit steering rack to chassis using 3 special polyproplene bushes
Fit brake and clutch pedals to chassis on cross shaft
Fit a new servo and master cylinder to mounting plate on chassis
Fit 3/16 Kunifer brake lines to inside of the offside chassis rail using 12 clips (3 x T pieces will be required: (i) the brake light switch; (ii) separate rear calipers; (iii) to split front pipes from servo)
Install 2 front brake flexibles between brake lines and calipers
Fit fuel tank, contents sender unit and fuel pump to chassis
Fit 5/16 copper fuel line to chassis (leading from tank to offside of engine compartment) with 7 clips
Fit Suffolk engine mountings
Fit special bush to gearbox
Using a crane (hire item £15.00) install engine and gearbox as one unit (less carburettors and exhaust) - 3 mounting points
Install Suffolk modified propshaft
Install radiator mounting hoop; alloy radiator; hoses
Fit Jaguar exhaust manifolds and Suffolk 6 part stainless steel exhaust system
Fit 4 special splined wheel hubs including the dummy brake drums
Fit Suffolk SS100 18" road wheels with Blockley 5.50x18 6ply tyres
Arrange the painting of body shell; bonnet; doors
Fit main body unit to chassis (this is supplied complete with doors and fully predrilled (the body unit can be lifted onto the chassis in a matter of minutes)
Install chrome radiator shell onto the mounting hoop
Fit 4 handmade aluminium bonnet panels over engine compartment
Arrange trimming for interior: seats; carpets
Install wiring loom (the correct position and location of terminals is determined by using Suffolk diagrams as shown in the Customer Build Manual
Install handbrake and handbrake cable
Install floorboard set; gearbox cover; tunnel
Fit seat runners
Fit Jaguar engine with all operational ancillaries: coil; distributor; alternator; carburetors; manifolds; starter; etc.
Fit 4 bonnet catches to the bonnet including 4 hold down fasteners to chassis rail
Fit windscreen wiper spindles
Install instruments; switches into predrilled dashboard
Fit hood mountings; rear hood rests
Fit steering column; indicator stalk
Fit carpets; door linings
Fit door locks; latches
Fit windscreen; mirrors
Fit hood frame; mohair hood
Fit dummy tank vent
Fit spare wheel to rear
Fit lamp bar; front valance; starting handle eye
Fit radiator cap; badge
Fit steering wheel and boss
Fit headlights; front lamps; rear lamps, side lights; indicators
Fit tonneau cover; hoodbag
Fit rear view mirror
Check ALL fluid levels carefully.
Fit battery and turn ignition on
BEFORE DRIVING: Check oil pressure; water temperature; brake pedal pressure .
Arrange MOT test

From now: Heaven is any road you are driving on!