Suffolk C-type User Manual
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Suffolk C-type User Manual

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Build Manual
Suffolk C-type
Suffolk Sportscars Ltd
P.O Box 100, Woodbridge, IP12 9BA
www.suffolksportscars.com
Admin & Sales tel: 07967 339424 - email: roger@suffolksportscars.com
Workshops tel/fax: 01728 745055 - email: theworkshop@suffolksportscars.com
Issue No: 011014

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  • Page 1 Build Manual Suffolk C-type Suffolk Sportscars Ltd P.O Box 100, Woodbridge, IP12 9BA www.suffolksportscars.com Admin & Sales tel: 07967 339424 - email: roger@suffolksportscars.com Workshops tel/fax: 01728 745055 - email: theworkshop@suffolksportscars.com Issue No: 011014...

  • Page 2: Foreword

    Dear Customer, Suffolk C-type Owners Build Manual We hope that your chosen project of self building a Suffolk C-type will be as enjoyable as driving your car following it’s completion. Our emphasis is very much directed towards supplying the parts and assisting self build owners in the satisfactory completion of their C-type.

  • Page 3: Table Of Contents

    Contents Page Foreword ..........................2 Contents ..........................3-4 Picture CD ..........................5 Origins and Spec ........................6 1. Introduction ......................... 7 2. Garage and Tools ........................ 7 2.1 Principal Tools Required .................... 7 3. Fasteners ..........................7 4. Building up the Chassis plus Suspension and Final Drive ..........8 4.1 Chassis Kit ........................
  • Page 4 22.1 Wheels and tyres ..................... 39 22.2 Tonneau cover ......................39 Parts List ........................40 – 43 C-type Hardware List ..................... 44 - 51 Rubber & Polybush Types and Positions ................52 Photo Index ........................... 53 Photos ........................54 - 63...

  • Page 5: Picture Cd

    Mount picture cd here...

  • Page 6: Origins And Spec

    History tells us everything, books like Philip Porter’s 1995 ‘Jaguar Sports Racing Cars’ inspire many readings to absorb the wonderful atmosphere. A few lucky guys like myself have the team and the tools to recreate the amazing Jaguar C-type. Can any other reproduction of a Le Mans winning car inspire so much and yet come at a price that is such a small fraction of the original’s value.

  • Page 7: Introduction

    Suffolk Sportscars for advice first. 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.

  • Page 8: Building Up The Chassis Plus Suspension And Final Drive

    Building up the Chassis plus Suspension and Final drive Chassis kit Parts required 001 Main tubular chassis Front frame C/W lower fixings 2 of 5/16” UNF x 1” Upper fixings C/W inner Wishbone mounts Rear frame C/W Lower fixings 2 of 7/16” UNF x 3” Upper fixings 2 of 3/8”...

  • Page 9: Front Suspension

    13. With the rear frame removed you can rivet on the final pieces of the belly pan set comprising the boot floor (this will need flexing to pass through the frame) and the rear bulkhead which rivets on the outside of the frame. 14.

  • Page 10: Rear Suspension And Final Drive

    12. The top ½” UNF x 3” bolts locate into the cross brace bars (003). The rear bar may need a couple of washers/shims to fit the gap and is best left out until the engine is fitted, whilst the front bar can be fitted but in co-ordination with the front frame.

  • Page 11: Brakes, Clutch And Pedal Box

    the front-end poly bushes and slide them in followed by the metal sleeve and do the same with the smaller rear bushes. You can now grease the rear radius arm mount pins on the rear end of the chassis and slide on the radius arms, locate with washer, castle nut and split pin. 3.

  • Page 12: Clutch

    Clutch Parts required: - 042 1. Start off by removing the blank from the clutch master cylinder (042) and screw in one end of the clutch flexi hose. On the other end screw on the Banjo union supplied with the clutch slave cylinder (this will be connected up once the engine and gearbox assembly has been fitted).

  • Page 13: Handbrake

    “P” clips to secure to the chassis but then removing this pipe for ease and safety of fitting the body. This pipe runs along the outside of the chassis above the body-mounting flange. Handbrake Parts required 044 1. The handbrake mounts to the inner left hand chassis rail, beside the gearbox with the top face of the mount flush with the top face of the “C”...

  • Page 14: Rdh Brake Pipe Locations & Sizes

    C-type - RHD Brake/Fuel Pipes Locations & Sizes (XJ6 Master Cylinder and optional servo) FRONT SECTION CODE DESCRIPTION LENGTH THREAD UNION FLARE MASTER CYLINDER TO 8” 10mm LATE TYPE MALE SINGLE SERVO or DIRECT TO MASTER CYLINDER 3-WAY BRAKE SWITCH...

  • Page 15: Engine And Gearbox

    Engine and Gearbox Parts required 001 plus (gearbox brackets and engine bay brace) 052,079,081-086. Mating engine to gearbox 1. If not already fitted, lightly copper grease the pivot ends of thrust release bearing (085). 2. Place the release bearing over the gearbox input shaft and locate pivots in the release lever. Locate the straight ends of the spring retaining clips in the ends of the pivot and rotate the cranked ends around behind the release lever until they click into the location points.

  • Page 16: Steering

    2. As the unit enters the chassis lower it slightly to get the gearbox under the bulkhead cross member but don’t let the sump get too low and hit the front cross member. When you have nearly got the gearbox back far enough you need to lift the gearbox as it comes back and drop it through the mounting plate hole.

  • Page 17: Ancillaries (Pre-Body Fitting)

    will have several lengths of braided fuel hoses, the two you need here are 400mm from fuel tank to fuel pump and 800mm from fuel pump to rear of metal fuel pipe. The metal pipe supplied runs from front to rear of the chassis alongside the brake pipe, as is best left off like the brake pipe until the body is fitted although trial fitting is a good idea.

  • Page 18: Alternator/Dynamo

    4. Start off by thread locking the 12 x M8 studs into the inlet manifold. Hang on the three double “O” ring seals. You can also fit the thermostat and housing using sealing compound on both sides of the gasket before fitting. 5.

  • Page 19: Radiator

    2. The threaded end of the adjuster needs a 3/8”UNF nut screwed on followed by a plain washer then the alternator/dynamo mounting block (the block should hang down from the adjusting bar with the cut out at the front for the alternator to sit in). Follow this with a plain washer, lock washer and 3/8”UNF nut.
  • Page 20 4. Once happy with the fit remove the panels and mark at equal intervals where they will be riveted to the GRP and drill to size for your rivets, lay the panels back in the bonnet drill the GRP and temporary bolt the panels in through a few holes while you carry on with the other panels in the same way.
  • Page 21 16. With the hinges mounted to the door/s offer them up to the centre body section and ensure the front end has a fairly even panel gap and is level with the top of the body before marking around the front of the door hinges, remove the doors and with careful measurements mark and drill positions for the hinge bolt holes.

  • Page 22: Fitting Body Centre Section

    Fitting body centre section Parts required 141,039(R1),089 1. Before any parts can be fitted that overhang the chassis the body centre section needs to be fitted. Prepare for this by drilling holes or snipping the lower inner corners of the driver’s side front and middle alloy panels to allow the brake and fuel lines to pass through.

  • Page 23: Ignition Coil

    pipe can be secured down to the chassis with “P” clips. At the front the pipe needs to turn up and join the braided hose to connect with the fuel filter (250mm braided hose). The fuel filter is fitted on the chassis rail below the carburettors on the rear of two mounting plates and can be secured using two 5/16”UNF bolts and Nyloc nuts.

  • Page 24: Electrical And Wiring

    2. The central hole in the main dash is for the lamp switches, the alloy switch panel can be offered up and the mounting holes drilled. Centrally above this is the map reading lamp position; these holes can be drilled too. 3.
  • Page 25 (from top) 2x Red/White Right marker lamps Red (use short length of cable to link to fuse below) 2x Red/Black Left marker lamps 3x Blue/White Main beam lamps 2x Blue/Black 2x Blue/Red Dipped beam lamps Blue/Orange Bottom fuse box 4x Green Brake lamps White ( use short wires to (from top)
  • Page 26 Blue/Red Dip beam Red/Black Side/marker lamp Green/Red Indicator As with the right side, bolt this earth to the chassis webbing cleaning off the paint to provide a good earth and protecting with grease once connected. The final part of the front wiring loom is the Alternator/Dynamo connections. If you’re using a Dynamo or Alternator dressed as a Dynamo then the two eyelets will connect to the rear of the unit, (small eyelet small stud, and large eyelet large stud).
  • Page 27 To finish this area of the dashboard you will need to connect up the mechanical parts of the gauges. Start by drilling a hole in the bulkhead behind the speedometer. This hole could take the speedometer cable (104), water temperature capillary tube and oil pressure pipe (both come with instruments) into the engine bay or you could use separate holes if required.
  • Page 28 Slate grey/Red Indicator warning lamp Yellow Overdrive ignition live in Yellow Overdrive live out Purple Map/Bonnet lamp live in, terminal 4 (connecting this switch like this means you can’t leave bonnet lamp on without map lamp being on) Purple/White Map lamp live out, terminal 7 Purple/White Bonnet lamp live out, terminal 8 Blue/Black...
  • Page 29 BATTERY MASTER KEY SUFFOLK C-TYPE C TYPE WIRING DIAGRAM STARTER SOLONOID COLOUR CODES STARTER MOTOR MAIN FUSE R = RED B = BLACK BL = BLUE BR = BROWN G = GREEN AMMETER REGULATOR W = WHITE Y = YELLOW PU = PURPLE P = PINK...
  • Page 30 FUSE SIZES AND EXAMPLE LAYOUT RIGHT MARKER 5 AMP LAMPS RED/WHITE LEFT MARKER 5 AMP LINK TO ABOVE LAMPS RED/BLACK FUSE MAIN BEAM LAMPS 15 AMP BLUE/BLACK BLUE/WHITE DIPPED BEAM 2x BLUE/RED 10 AMP BLUE/ORANGE LAMPS IGNITION FEEDS 4x GREEN 10 AMP WHITE FUEL PUMP...
  • Page 31 Drill this hole to 25mm for wiring harness to fuse boxes and regulator Drill these four holes and insert nutserts to secure fuse boxes Cut out template or trace and cut out your own, use to position fuse boxes, regulator and wiring harness holes.

  • Page 32: Battery Tray, Battery And Cut Off Switch

    Battery tray, battery and cut off switch Parts required 109,110,111 1. The battery tray (110) fits on the right hand side in front of the drivers switch panel. First you will need to remove the body-mounting bolt that goes through the chassis rail just ahead of the driver’s side/switch panel as this is also used to secure the battery tray.

  • Page 33: Rear Valance And Spare Wheel Cover

    3. Next offer the door/s to the body and pass the hinge studs through the body. On the inside of the hinge studs fit on star washers (these help the hinges grip to the body) followed by the plain washers and Nyloc nuts.

  • Page 34: Bonnet

    These lamps can now be wired up according to section 13. The rear indicators (100) are fitted on angled alloy brackets that mount on the rear inner side panels just below the rear body so are discreet and don’t need holes drilled in the body. Rear reflectors (101) could also be fitted in the same way to save spoiling the rear body’s smooth lines.

  • Page 35: Interior Fittings

    down to and through the smaller hole, which should be fitted with a grommet. The wires can be run up the front frame to the junction box and joined according to the wiring instructions on page 19. Interior fittings 20.1 Interior floor and side panels Parts required 164,165 1.

  • Page 36: Seats

    1. We advise using a three-point harness; there are mounting points built in the chassis for this. The outer lower mounts are bolted directly to the chassis, the inner mounts are bolted on to an angle bracket first to bring them out to match the position of the outer mounts. This angled bracket is then bolted to the rear bulkhead.

  • Page 37: Front Grille

    Front Screen Parts required 143/4 1. If your body is not being painted by Suffolk Sportscars you will need to prepare the screen plinth (143) before painting by drilling in the required mounting holes. In the body mounting side you will...

  • Page 38: Transmission Cover Preparation Guide

    TRANSMISSION COVER PREPARATION GUIDE 1. REMOVE BASE FLANGE 2. TRIM REAR SECTION TO SAME ANGLE AS CHASSIS FOOT PLATE. A = STARTER MOTOR UPPER ACCESS HOLE - Ø40mm B = STARTER MOTOR LOWER ACCESS HOLE - Ø40mm C = O/D SWITCH ACCESS HOLE – Ø50mm D = OIL FILLER / LEVEL ACCESS HOLE –...

  • Page 39: Finishing Items And Extras

    Finishing Items and Extras 22.1 Wheels and Tyres Parts required 045-8 1. If your wheels (046) have been painted it is very important to remove any paint from the internal splines and the internal taper which meets with the hub and the external taper, which meets with the spinner.

  • Page 40: Parts List

    SECTION 1 Chassis / Suspension / Brakes Customer Location Estimated date of delivery NOTES   DESCRIPTION Strip/prepare/paint donor components Chassis inc. front & rear subframes, engine brace, prop shaft hoop & gearbox bracket. 001a Alloy Belly Pan panel set (9 piece) Paintwork to chassis Front upper wishbone cross brace bars x 2 Fr Lower wishbones x2 LH &...
  • Page 41 SECTION 2 Engine and Gearbox   Customer Location Estimated date of delivery NOTES   DESCRIPTION Engine Jaguar XK / XJ donor/ VSE Engine size : spec : Engine mounting rubbers x2 Engine mounting brackets x 2 + Rear steady bar, brackets and bushes Alternator or Dynamo bracket + adjuster Alternator or Dynamo Fan belt –...
  • Page 42 SECTION 3 Electrical Fittings / Instruments Customer Location Estimated date of delivery   DESCRIPTION NOTES Wiring Loom – braided Fuse Boxes x2 Control Box - Alternator Control Box - Dynamo Front Headlamps x 2 + mountings x 2 Front indicator Lights x 2 Rear Light stop/tail x 2 Rear Indicators x2 + brackets or special brake lamp/flasher relay ** Rear Reflectors x 2...
  • Page 43 Alloy Interior floor panel set Tonneau Cover + fittings LHD or RHD Black hardura for inside panniers Paintwork by Suffolk Sportscars approved Paint shop. Delivery to/from paint shop Registration No. Plates - front & rear (self adhesive plastic) Chassis plate - stamped...

  • Page 44: C-Type Hardware List

    C-­‐type   H ardware   l ist   Item Width Length Thread Type Notes Front frame 5/16 Hex head 5/16 Nyloc nut 5/16 Plain washer Rear frame Hex head Nyloc nut Plain washer 7/16 Hex head 7/16 Nyloc nut 7/16 Plain washer Engine Bay Brace 5/16...
  • Page 45 7/16 Plain washer Anti-roll bar ‘D’ brackets Hex head Nyloc nut Plain washer Anti-roll bar drop links 7/16 2 1/4 Hex head 7/16 2 3/4 Hex head 7/16 Nyloc nut 7/16 Plain washer Steering rack mount bracket 5/16 4 1/2 Hex head 5/16 Nyloc nut...
  • Page 46 7/16 3 3/4 Hex head 7/16 Nyloc nut 7/16 Plain washer Rear radius arm Castle nut Washer Split pin Rear tie bar 2 1/2 Hex head 2x 1/2 spacer Lock washer Plain washer 2 1/2 Hex head Nyloc nut Plain washer Pan hard rod 2 1/2 Hex head...
  • Page 47 Metric Plain washer Hex head Lock washer Plain washer Engine mount brackets 7/16 Hex head 7/16 Lock washer Engine rear steady 5/16 Hex head 5/16 Lock washer 5/16 Penny washer 5/16 Hex head Hex head Plain washer Lock washer Alternator bracket 5/16 Hex head Alternator...
  • Page 48 5/16 Lock washer Brass nuts Lock washer Exhaust silencer 5/16 Hex head 5/16 Nyloc 5/16 Plain washer Exhaust stabiliser 5/16 Nyloc 5/16 Plain washer Oil catch tank (Webers 50mm Metric Hex head only) Metric Nyloc Metric Plain washer Gearbox mount C/W Nyloc adapter Plain washer...
  • Page 49 brackets Metric Nyloc nut Metric Plain washer Pot rivet Rear Reflectors x 2 Metric Slot head Metric Nyloc nut Metric Plain washer Horn button Metric Slot head Metric Nyloc nut Metric Plain washer Battery cut out master Metric Slot head switch Metric Nyloc nut...
  • Page 50 Metric Plain washer Metric Coach bolts Metric Nyloc nuts Metric Plain washer +4 spacers Bonnet Stop Brackets 20mm Metric Pan head Metric Nyloc Plain washer Headlamp Perspex covers Self taping Bonnet top security straps 30mm Metric Coach bolt Plain washer Nyloc Bonnet Grille + fixings Nyloc...
  • Page 51 Metric Nyloc nuts Or rivnuts Metric Plain washers 25mm Metric Slot head Paint over Metric Nyloc nut Metric Plain washer Interior Screw Gearbox/propCover Seat buckets 15mm Metric Countersunk Seat Runners 5/16 1 1/4 Set screw Allen head 5/16 Nyloc nut 5/16 Plain washer Seat Belt Harness...

  • Page 52: Rubber & Polybush Types And Positions

    C-type – RUBBER & POLYBUSH TYPES & POSITIONS: POLY/RUB PART NO. POSITION ON CAR: QTY / CAR POLY SPF 0286 FRONT LR WISHBONE SHAFT TO CHASSIS (REAR BUSHES NEED TO BE MACHINED TO FIT) POLY SPF 0286 REAR TRAILING ARM PIVOT TO CHASSIS...

  • Page 53: Photo Index

    Jaguar XK engine and gearbox ready for dispatch ............59 Figure 19 Alloy radiator with temperature sender for electric cooling fan ........59 Figure 20 Engine right hand side ....................60 Figure 21 Rolt, Hamilton and Moss with the winning C-type at Le Mans 1953 .......60...

  • Page 54: Photos

    Figure 1 Engine Bay with optional air trumpet intakes – Webers Figure 2 Engine Bay with steel manifolds and exhaust system...
  • Page 55 Figure 3 Engine Bay Figure 4 Bulkhead fuse boxes and controls...
  • Page 56 Figure 5 Typical layout for fuse and junction boxes Figure 6 Dashboard and optional 15” Moto Lita alloy wheel...
  • Page 57 Figure 7 Rolling Chassis - bonnet removed Figure 8 Rolling Chassis...
  • Page 58 Figure 9 Near side showing optional passenger door Figure 10 Engine bay top view showing 2 SU carburettors and cold air box...
  • Page 59 Figure 111 Near side front suspension Figure 12 Dashboard interior layout with 15” 3 spoke wheel in black; also available in alloy with wood rim.
  • Page 60 Figure 12 Silver Suffolk C-type Jaguar Figure 14 Rear axle and brakes...
  • Page 61 Figure 15 Engine installation with triple Weber airbox and optional stainless steel exhaust manifolds. Figure 16 Engine installation showing 2” SU carburettors and optional air trumpets in place of conventional airbox with filter Figure 17 1953 Spec Suffolk C-type Jaguar...
  • Page 62 Figure 18 Jaguar XK engine and gearbox ready for dispatch. Figure 19 Alloy radiator with temperature sender for electric cooling fan Figure 20 Engine right hand side.
  • Page 63 Figure 21 Chassis and mechanical components overhead view excluding front and rear sub-frames Figure 22 Rolt, Hamilton and Moss with the winning C-type at Le Mans 1953...
  • Page 64 THIS PAGE IS INTENTIONALLY BLANK...

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