Let the Fun Begin - R400 Strip and Rebuild

[TwedleJoe]

Here we go!

 

I have just today completed a full strip of my 2011 R400 SV. I am down to 10 boxes of parts, a few odds lots that won't fit in a box, and a frame with panels as the starting point. The main reason for the tear down was to fix some inherent shortcomings but primarily to do 1) a custom inside and out paint job 2) upgrade the powerplant and 3) prove to myself I can still sling a wrench. I have not posted about the teardown as I suspect anybody with a basic toolkit can disassemble anything short of the space station. The art is in putting it back together!

 

Learnings to date

 

You cannot have enough 10MM, 13MM and 17MM tools

How to cut wire ties and drill rivets

Caterham has as many dead end wire "spares" as used connections

 

I am considering taking the time to do a build log/blog as I reassemble/upgrade on the way back up and am curious if there is any interest in others watching and commenting on the progression?? Lord knows the uniqueness of our cars requires a "community" of experiences and resources to pull it off. In return, I'll ask for opinions, advice, resource connections and the like.

 

If nothing else, wish me luck! I have a bet I can pull this off in less than a year...….

 

http://www.usa7s.net/vb/attachment.php?attachmentid=14683&stc=1

 

Twedlejoe

[Vovchandr]

Cool! Good luck. Subscribing

[wemtd]

I definitely recommend a time-lapse photo like this smart person did

I tried to make one of my build: set up a camera to take photo every 3min for entire build. I then compressed all photos into a cine/film and adjusted the playback speed.

The two main problems i encountered was moving my build 1/2 way through but didn't record stuffing the chassis into a u-haul trailer without wheels, etc. Second problem was builder wearing a balaclava in his unheated arctic garage for the first half, then my finest lawn-mowing ensemble for the completion.

 

good luck!

[Kitcat]

Definitely interested in all of the gory details. And I agree, remembering how it all goes back together is a major challenge (take lots of pix!). Seems like having a large (and heated- thx Paul) workspace is essential? Given how hot the cockpit gets (its really an extension of the engine bay), what about adding some heat shield materiel while your at it? What will you be doing to add hp? What color or color combos are you considering?

[Kitcat]

Definitely interested in all of the gory details. And I agree, remembering how it all goes back together is a major challenge (take lots of pix!). Seems like having a large (and heated- thx Paul) workspace is essential? Given how hot the cockpit gets (its really an extension of the engine bay), what about adding some heat shield materiel while your at it? What other shortcomings are you focusing on? What will you be doing to add hp? What color or color combos are you considering? So many questions:)!

[JohnCh]

Build threads are too few and far between. I'd love to better understand your plans for the upgrades and then critique, er...I mean observe this from the sidelines. :jester:

 

-John

Edited October 22, 2018 by JohnCh
can't spell

[Croc]

...prove to myself I can still sling a wrench.

 

Thats easy. I can sling mine across the garage in frustration when I do something stupid! :jester:

[drewbrese]

I dig it. Subscribing.

[TwedleJoe]

Awesome guys and thanks for the feedback. I am going to get a Word Press site up and will share the link here.

 

As for tear down pictures, I have around 600 all catalogued to a tear down log I kept up through the process. Note: everyone needs a big whiteboard in their garage. Also inventoried parts as I boxed them and started a "must upgrade" and "nice to upgrade" list. I have decided the theme will be a GT style car versus a full on track car; i.e., keeping the Caterham 6 speed versus sequential and not stiffening the suspension to a bone jarring level. As for the motor, undecided but looking at induction methods since I have all that SV room to put the plumbing. Researching turbo install so any actual experience would be appreciated. Will dry sump and beef up the bottom end while the motor is out in hopes I never have to see it again.

 

Here is a list of immediate to-dos before going to the paint shop.

 

Install new custom-order scuttle so I can have one for the aero less the wiper/washer holes and one for the windshield if I ever put is back on. I took the firewall section (vertical) off the scuttle and will rivnut them together (instead of riveting) to facilitate a quick change out.

 

Ordered wheels from Force Racing in the UK that does mini cooper builds, Light, durable, top quality and race proven. Need them in as I'll match the purple centers to part of the new paint scheme. I already have Quantum dampeners from Meteor Motorsports and the metallic purple looks awesome against a primary black background.

 

Pull the lowered floor pans and have them sprayed with a tougher material. I found a bed liner-type spray that is fairy light weight and super durable. Also gonna beef up the seat area of the pan and straighten out the dip from my big arse rounding it out going over bumps.

 

KitKat - note the heat shield material on the foot wells and down the tunnel. I does make a difference.

 

More coming soon!

[wemtd]

... I keep a supply of sharpie markers and crystal light/drink mix containers on hand: translucent so you can mostly see what's in them, they stand up on the shelf well and hold most of the nuts/bolts of my car (I've had it apart once or twice). I find these work better than zip-loc bags. most of the bigger parts are easily identified by sight and can go in boxes: eg: drink container for fore differential mounting bolts, diff is hard to miss-identify sitting on the bench.

 

good luck, have fun, and keep us updated on your progress.

p.

[Brightonuk]

Lot and Lots of step by step photos please

Especially mistakes (helps a lot)

 

That look like a Harbor Freight Tool Seat hope your wrenches are not from the same place.

Edited October 23, 2018 by Brightonuk

[Lonnie-S]

What's the bedliner spay you're going to use, Joe? I'm looking for something to use on my Locost build.

 

Cheers,

 

Lonnie

[Wings Aviation]

Hi, I have a Turbo R400 if you have specific questions. I’ve tried various setups and maps, it makes for an extremely quick car if done properly.

[CarlB]

I am very interested in your rebuild, and want to do much the same to my car. Thank you for sharing. I would be very interested in seeing your disasembly pictures.

[CarlB]

Your build is inspiring questions. I want to replace my dash panel so I can change the guage layout. You can't get the dash out without removing the cowl first. Your picture shows the fire wall side of the cowl in place. Can the cowl be removed with out drilling out all the fire wall rivets? Is it possable to remove the cowl with the firewall in place?