SUMOMKII MANUAL

JAGUARVERSION

The Jaguarversionof the SUMOMk.2was first introduced in Jan

1993.These instructions do not detailthe f ittingof all possible
engine/gearbox Thesewillbe addedto futureeditions
configurations.
and photographs
as and when information becomeavailable. When
buildingyourJaguarbasedSUMOyou shouldcheckwiththe factory
to ensureyou havethe mostup-to-date
instructions.

ISSUE1 86 pages MARCH1993

Pilgrimare preparedto exchangeany outdatedmanualfor an up to

date version.A chargeof t6 is madeto coverour administrative
expenses.

Pleasenotethat to reduceour artworkpreparationcosts,thereare

severalpagesin this manualwhich also relateto other models
producedby Pilgrim.Pleasedisregardreferences to all Cortinaor
GranadabasedSUMO's

ThisManual.
Thismanualis a cheapermassproduced versionof ourstandardspiro-
boundedition.Tohelpreduceprintingcosts,we havelefta fewpages
out.In particular
andmostnotablywe haveonlyincluded fitting
forthe FordsmallblockWindsorandRoverV8 engines.
instructions We
havealsoomittedpagesdealingwithourtermsof business, fittinga
chassisnumber,reanruardhingingbonnet,tonneaucover,hoodpoppers
pages.
anda coupleof other(lesssignificant)

Allthesepagesareincluded in issue2. Weshallgladlyupgrade this

manualto issue2for the abovementioned administrationchargeof f6.
However,we shallnotexchange thismanualfor oneof anothertype.

SussexBNsgXJ
PilgrimCarsLtd., Unit14, MackleyEstate,SmallDole,Nr.Henfield, Tel: (0273)493860
 Dear Customer,

Theseinstructions are now offered free of charge,and are provided as information only. They
cover the Jaguarbuild for the Mk2 Pilgrim Sumo, but also form the main part of the
instructions for building the Jaguarbasedmodel using the Mk3 Pilgrim Sumo Chassis.

We at PILGRIM careabout quality and believeit is not just skin deep.True

quality extends from the high gloss exterior finish right through to every last
detail of the mechanicafassembly.

A large number of people have built cars from PILGRIM kits and would
testify that they are as much fun to build as they are to drive when finished.

We hope that you will find theseinstructions clear,conciseand

informative, but somecustomersdo get "stuck" at some stage.This is why we
have a "help-line", manned by friendly, knowledgeablestafiwho can guide you
through any un-foreseenproblems. It is good to know they are there to help even
if the majority of customers don't need them.

Yours sincerely,

D. TANNER. BSc

P.S.If you disgover any omissions, shortcomings, unclear sections or

inaccuracies,then pleaselet us know (preferably in writing) . This will enable us
to update future editions.

sussexBNsgxJ
Pilgrimcars, Unit14, MackleyEstate,smallDole,Nr.Henfield, Tel:(0273)493860
3

ASSEMBLY
INSTRUCTIONS
Introduction
Safety.
Our kitsare amongstthe safestto be foundwithinihe
specialistcar industry.We spenda greatdeal of time and
moneyhavingour kitsexamined,testedand approvedby
variousBritishand Europeanroadtrafficauthorities. The
SUMO has beentestedby the Dutchroadtrafficauthorities
and has beengrantedfull Dutchtype approval.Seat belt
anchoragetestswere conductedto the rigorousrequirements
of ECE regulation14.02and passedwith a comfortable
margin.Variousothertests havebeenconductedby the very
strictGermanTUV authorities. We intendto imolementall the
requirements of full Britishand Europeantype approval.To
that end we have improvedthe safetyspecificationof the
SUMO by incorporating testedand approvedburstproofdoor
lockingmechanismsand strikerpins.We havepositionedthe
fuel tank in a well orotectedareaand orovideda metal
bulkhead"firewall"separatingthe occupantsfromthe engine
comoartmentin the eventof an enoinefire.
We are extremelyconfidentthat no otherspecialistkit car
producercan boast a betterlist of safetyspecificationsthan are
presenton our SUMO.
Pilgrimis a memberof STATUS,an organisation whichsets
industrystandardsand is very consciousof the latestsafety
requirements in the automotiveindustry,bothat homeand
abroad.
SussexBN5gXJ
PilgrimCarsLtd, Unit14,MackleyEstate,SmallDole,Nr.Henfield,
4
.
SECTIONi
INTRODUCTION
Chassis Design
The designof the chassisdoes not easilyfall intoany pafticular
grouping.lt has a ladderframeat groundlevel,a very strong
backbonewith steelbulkheadsand floors.Bracingtubesare used
to transferloadsdirectlyintothe bulkheadsand tunnel.
In otherwordsthe chassisusesa combination of ladderframe,
spaceframeand monocoqueconstruction techniquesto provide
a very simpleyet amplystrongand cost-effective
structure.
Becauseof the highsheetmetalcontentwe offeran optional
chassisgalvanisingservicewhichwe highlyrecommend.
Buildability.
The use of Fordsuspensionand steeringcomponentsmakesthe
SUMOparticularly easyto buildin comparisonwithotherlarge
enginedkits.
Evenour Jaguarbasedkit is very straightforuuardto buildbecause
are clearand conciseand the customeris not
its instructions
requiredto makeany modifications to the Jaguarequipment.
lf you are comparingour kitwith thatof anothermanufacturer,
pleaseensurethat you accuratelycomparepricesand readin
detailtheirassemblyinstructions. We are confidentthat our kit
offersthe bestvalueand unrivaledqualityand buildability.
The chassisitselfis very straightfonvardto assemblewith pre-
drilledmountingsfor nearlyevery component.The chassisis a
self-containedunit,it is possibleto fit all the mechanical
componentsincludingseats,steeringcolumn,batteryand wiring
loomand thendrivethe chassiswithoutthe bodyfitted.
The factthat it is possibleillustrates
the very completenatureof
the PilgrimsuppliedSUMOMk 2 chassis.
Engine Choice.The SUMO Mk 2 is offeredwith 5 chassis
variations.
Eachchassisvariationis the subjectof a differentconstruction
manuar.
Theseare:-
Cortina Based r Acceptsall Corlinaenginesfrom 1600cc to
2300cc V6.
GranadaBased :- Acceptsall Coftinaand Granadaenginesfrom
1600 cc up to 3000cc V6.
Rover V8 i UsesmainlyGranadarunninggear in conjunction
with an SD1 Rover3500cc engineand gearbox.
Scorpio 2900 EFI i UsesmainlyGranadarunninggearin
with Fordslatest"green"engine.Thisvariationwas
conjunction
designedwith exportmarketsin mind.
Jaguar Based:-UsesJaguarsuspensionin combination
with
virtuallyany V8 or V6 engine.
Tel:(0273)493860
 ASSEMBLY sEcTroN
ii
INSTRUCTIONS CONTENTS

Section Section
1 . 0 GeneralInformation 6.0 Trimming and Finishing cont.
Contains
details
in relation
to safetyetc. 6.12 Mirrors
6.13 Grilles
6.14 Towhitch
2.0 Parts Required 6.15 Windwingsandvisors
2.1 Kitpafts
2.2 Mechanicalparts
2.3 Toolsrequired 7.0 Weather Equipment Fitting
7.1 Hoodframe
7.2 Hoodfitting
3.0 RollingChassis 7.3 Tonneau
3.1 Partspreparation
3.2 Frontsusoension
3.3 Rearaxle 8.0 Dealing with Fibreglass
3.4 Handbrake
8.1 Strength andhandling
3.5 Engineandgearbox
8.2 Fixingto andrivetting
3.6 Pedalboxandservo
8.3 Flashlineremoval
3.7 Radiator
8.4 Accidentdamage
3.8 Brakepipes
8.5 Bodystorage
3.9 Exhaust pipes
8.6 Rivettingfibreglass
3.10 Prooellershaft 8.7 Drillingandcuttingfibreglass
3.11 Wheelsandtyres
8.8 Firewarning
3.12 Steeringcolumn 8.9 Pinholes
3.13 Throttleandclutchcables
8.10 lmooftantnotes
3.14 Heater
8.11 Paintingfibreglass
3.15 Chassis number

9.0 Technical Specitications

4.0 Body Fitting
4.1 Mainbodytub
4.2 Demisters
10.0 Registrationof Finished Car
4.3 Windscreen
4.4 Doors 10.1 lnsurance
4.5 Innerbodypanels 10.2 Engineersreport
4.6 Windscreen 10.3 M.O.T.
wipers
4.7 Boot 10.4 LVLO
4.8 Bonnet to 'Q' plate
10.5 Alternative
4.9 Roll-over 10.6 lllegalregistration
bar
4.10 Petroltankandcap
11.0 FinalAdjustments
5.0 Electrical Installation 11.1 Headlamps
11.2 Enginetuning
5.1 lgnition
coil
Lamps 11.3 Tracking
5.2
11.4 Bolts
5.3 Battery
Windscreen 11.5 Soares
5.4 washersystem
55 Loomfromdonorcar
5.6 Newloom

6.0 Trimming and Finishing

6.1 Carpet
6.2 Dashboard
6.3 Steeringcolumncovers
6.4 Gaiters
6.5 Doortrimoanels
6.6 Seatbelts
6.7 Seats
6.8 Nudgebars
6.9 Sioneguards
6.10 Sidevents
6.11 Badges

SussexBN5gXJ
PilgrimCars, Unit14, MackleyEstate,SmallDole,Nr.Henfield, rer Q73)493860
 ASSEMBLY 1
SECTION
INSTRUCTIONS GENERALINFORMATION

#CiMffi
of Quality
Guarantee
Policy Responsibility
developandimproveits products
Pilgrimpolicyis to constantly of the builderto ensurethatall the parts
It is the responsibility
to keeothemaheadof ourcompetitors. TheSumowas aresuitablefor useandare usedcorrectly, withall return
refinedduringthefirstfew monthsof manufacture. The springs,lockingwashers,splitpinsandothersafetydevicesin
resultingcurrentkit,we believe,fitstogetherperfectly.The theirrelevantplaces.Pilgrimcantakeno responsibility for any
qualityof ourbodywork mouldings andourchassis jigsare accident,lossor injuryresulting fromanyproductwhichhas
secondto none. beenmodified, assembled incorrectlyor assembled withparts
notrecommended in theseinstructions.
Only the Best
Theseinstructions detailthe bestwayto assemble our kit. Safety
Therearecheaperpartsavailable andalternativetechniques. Whenworkingon anymotorvehicleyoushouldkeepthe
However, if youdecideto useor employthemyou maymake workingareacleanandtidy.Glovesshouldbe wornwhen
problems foryourself
elsewhere in thebuild-up.Our Help-line handlingsharpand roughparts.Protectiveshoesshouldbe
staffmaynotbe ableto adviseif youdeviatefromthese wornwhenhandlingheavyparts.Beforeworkingunderany
instructions. Conversely,if youfollowtheseinstructionsto the securelyon blocksor stands
vehicleit shouldbe supported
letter,we arecertainol yoursuccessandof ourabilityto help fiacksshouldnotbe reliedon).Whencutting,drillingor
you in timesof need. grindingyoushouldwearsuitablebreathing apparatus andeye
protection.
Honesty
Unlikemanyothercompanies we produceverydetailed Specifications are subiect to change
instructionsandin thempointoutthe realcosts,problemsand Pilgrimkitsare amongstthe bestavailable on the market.They
deficienciesin ourproducts.lt wouldbe naiveto believethat arecontinually revised,improvedandalteredin orderto make
similarproblemsare notevidenton similarproductsproduced thembetter,easierto buildor cheaperto produce.We reserve
by competing companies.lt wouldalsobe naiveto assume the rightto alterourspecificationswithoutgivingpriornotice.lt
thata lessdetailed(thinner)manualimpliesthatlessworkis shouldbe understood thatPilgrimare underno obligationto
requiredin itsbuild. afterit hasbeensoldto the
modifya kit to a laterspecification
customer.
Confidence
We areso confident thatour kit is straight-forward
to buildthat Check before you buy
we guarantee to finishbuildingit for youif youget stuckfor Thegeneralstandardof fit andfinishof Pilgrimkitsis very
anyreason(including lackof time,illness, good.Thecarsavailable at ourworksfor demonstration,or
changein circumstances or anythingelse). Naturally we displayedin our brochures for special
are notsingled-out
chargefor sucha serviceat ournormalgaragerate(currently treatment. of whata
lt is trueto saytheyare representative
t17 perhour,butsubjectto change).Obviously we charge customercanachievegiventhata reasonable amountof time
extrafor materialsandpartsusedat our normalretailprices. is spenton the buildandthatcareis takenduringassembly.
Thisguarantee meansyoudo notriskbeingleftwitha pileof Thecustomershouldexamineourdemonstration vehicleto
unfinishedpartsin yourgarage. satisfyhim/herself thatwhatis beingsoldis whatis required.

Quick Assembly Order parts well in advance

lf a Sumokit is returnedto us for finishingwe guarantee
notto Pilgrimcarrymanythousands of poundsworthof stockto
chargefor morethan160hoursof labourto bringthe carto a satisfycustomers requirements. However, likemostcompanies
fullyfinishedstate.Thisappliesevenif we haveto stripthe we do haveproblems fromtime-to-time particular
in obtaining
carand re-buildfromscratch,butexcludestransportation, items.To helpbothyouandus,we requestthatanyitems
polishing andpainting. requiredafteryou purchase the kit areorderedin writingat
In otherwordswe guarantee thata Sumocan be builtby our ' least4 weeksbeforeyou needthem.Thisparticularly applies
factorystaffin 160hoursfrompre-prepared parts. to fabricitemssuchas hoods,seatsandcarpetswhicharenot
manufactured by us andareavailable in too manytypesand
Satisfaction coloursto holdall variationsin stock.
lf, in yourdealingwithus youare nothappywithanyof the
partswe supply,youcanreturnthemfor exchangeor refund Read our Terms of Sale
(inthe caseof refundsa smallhandlingchargeis made). Pleasenotethatall itemsaresoldby Pilgrimin accordance
Pleasekeepreceiptsfor proofof purchase. withtheirtermsandconditionsof sale(alsorelerredto as
terms of business).
In order to protect both you the customer, and us
the manufacturers, we would like to clarify the Withthatseriousbusinessoutof theway,we wishyouevery
following points: yourPilgrimkit.Remember
successin assembling thatif you
haveanyproblems we canbe contacted by phoneduring
Theseinstructionsarenot intended to be an authoritative
Theyare,we hope,a sensible normalworkinghours.
referenceon car mechanics.
andlogicalsequence whichshouldenablean
of instructions,
butotherwise
unskilled, practicalpersonto assemblea car
usingour kit andnewor usedmechanical components and
accessories, as listedwithinthismanual.

SussexBNsgXJ'
PilgrimCars, Unit14, MackleyEstate,SmallDole,Nr.Henfield, Tel:(0273)493860