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Pokey

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Ok Greg - it's been a long rainy weekend. Perfect weather for some build progress...let's see it :-)

 

Cheers,

-Bruce

 

It was a productive weekend Bruce. Taxes are done and that black Subaru you saw in my driveway made it to my son's place under its own power. I also managed to grab a few hours to work on the Seven and now have the front suspension assembled if not fully torqued. Despite taping and taking care, I found it difficult to not have some paint damage behind the nut on the front upper wishbone. Granted it is behind the nut and hard to see, but it is a little mystifying that there is about one mil of space between a nut, aluminum skin and the bracket for the wishbone. No idea why the factory doesn't make the hole in the skin a little bigger so the skin can flex behind the bracket rather than sit on top and get pinched.

 

I am learning though. Whereas in some vehicles I would assume tolerances were such that at the right angle and with some gentle force things will go together, Caterham tends to do things a little differently. I've now run into two situations where a little filing made more sense than a lot of force. Some of the issue with tolerances seems to be simply paint.

 

Speaking of paint, I read somewhere that the chassis is powder coated but to my eye it is paint. The inside of the upper shock mount flaked off like paint with bushing contact, and I've noticed some very minor chipping elsewhere. I realize that once on the road the chassis is going to get chipped, but being a bit detail orientated (aka anal) I've been touching up anyplace where bare steel is exposed. Not sure what you pros use, but the original formulation of Rust-Oleum in satin is a good match.

 

IMG_3248.jpgIMG_3250.jpg

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Its fair to say that Caterham kits are not quite like Ikea product assembly.

 

I think you need some build inspiration right now. When you are finished, Bruce will give you some coaching and you will have your 420R performing like this 420 is.

 

 

 

 

 

Keep the good work coming!

 

:seeya:

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Its fair to say that Caterham kits are not quite like Ikea product assembly.

 

I think you need some build inspiration right now. When you are finished, Bruce will give you some coaching and you will have your 420R performing like this 420 is.

 

 

 

 

 

Keep the good work coming!

 

:seeya:

 

Thanks Mike. I enjoyed that.

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How about a game of name that part? I found this in my box of shortages:

 

IMG_3259.jpg

 

This foot long piece of rubber trim doesn't seem to have a match in any other box, and I've not found a reference to it in either build manual. Someone who blogged about building a 420R has a description of trim around the body panel openings for the front suspension, but this wouldn't look to be for that purpose, there wouldn't be enough of it anyway, and I'm thinking that trim is strictly for the IVA in the UK?

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It looks like the scuttle edge trim - no where near enough of it mind you. Technically it is an SVA bit but it is good for finishing off the dash area and prevent paint chips on the edge facing the driver. I installed it on my US Caterhams for that reason alone although I forgot to on the UK 420R.

 

https://caterhamparts.co.uk/scuttle-panels/3642-edge-trim-rubber-black.html?search_query=scuttle&results=19

 

Photo of the edge trim installed

 

images?q=tbn%3AANd9GcS9ePc8l0dMk2UQlMIlZUZdMYncp61mN4xr82-4A-iuCK7Tj9_U

 

 

Edge trim on my 2010 silver CSR

 

2h1N3oy.jpg

 

 

My 420R dash without the edge trim installed

 

bJgfVyb.jpg

Edited by Croc
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How about a game of name that part? I found this in my box of shortages:

 

[ATTACH=CONFIG]16613[/ATTACH]

 

This foot long piece of rubber trim doesn't seem to have a match in any other box, and I've not found a reference to it in either build manual. Someone who blogged about building a 420R has a description of trim around the body panel openings for the front suspension, but this wouldn't look to be for that purpose, there wouldn't be enough of it anyway, and I'm thinking that trim is strictly for the IVA in the UK?

It maybe the trim for the air inlet box, item 4 on page 31 of the assembly guide?

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It is the trim for the air box. I scratched my head for a couple days on that also. Looks nothing like the picture in the guide... LOL. Also don't torque down the rack until later. You WILL need to loosen it to line up the steering column with the U-joint. I tried my best to "eyeball it" but needed to twist the rack later anyways... I waited to torque a lot of the suspension bushings until it was on the ground with the engine in. With the suspension hanging,(upper and lower a-frames, radius arms etc.) I didn't want to tighten everything to spec at their lowest point of travel, then have them damaged after it was on the ground.

The steering column bushings were a real pain! I wish i had a nickel for every time I pushed the one just behind the dash thru. Use plenty of lube!

Also. I installed probably 95% of the heater and radiator house before putting the engine in. I have no idea how they expect you to get some of them in after the engine is in the car!. Like the "U" hose that's practically under the battery. Sheesh.

 

 

Keep us posted. Good luck! I've got a lot more advice of you need it.

Kenny

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It is the trim for the air box. I scratched my head for a couple days on that also. Looks nothing like the picture in the guide... LOL. Also don't torque down the rack until later. You WILL need to loosen it to line up the steering column with the U-joint. I tried my best to "eyeball it" but needed to twist the rack later anyways... I waited to torque a lot of the suspension bushings until it was on the ground with the engine in. With the suspension hanging,(upper and lower a-frames, radius arms etc.) I didn't want to tighten everything to spec at their lowest point of travel, then have them damaged after it was on the ground.

The steering column bushings were a real pain! I wish i had a nickel for every time I pushed the one just behind the dash thru. Use plenty of lube!

Also. I installed probably 95% of the heater and radiator house before putting the engine in. I have no idea how they expect you to get some of them in after the engine is in the car!. Like the "U" hose that's practically under the battery. Sheesh.

 

 

Keep us posted. Good luck! I've got a lot more advice of you need it.

Kenny

 

We have a winner! You just saved me a lot of head scratching trying to figure out what this random bit of rubber in the shortages box was for.

 

I've already torqued the rack not knowing better, but did lay the steering column in to get alignment. Fingers crossed. For the suspension I removed the shock from the top mount and jacked the bottom wishbone to horizontal before torquing. I've made the assumption that horizontal is the neutral position... if it isn't I would appreciate no one telling me.

 

I'm going to do as you suggest and route hoses first, thanks for the tips Kenny, much appreciated.

Edited by Pokey
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It maybe the trim for the air inlet box, item 4 on page 31 of the assembly guide?

 

I was reading from the bottom up, so it looks like sf4018 got there before Kenny. Bragging rights to you both!

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It looks like the scuttle edge trim - no where near enough of it mind you. Technically it is an SVA bit but it is good for finishing off the dash area and prevent paint chips on the edge facing the driver. I installed it on my US Caterhams for that reason alone although I forgot to on the UK 420R.

 

https://caterhamparts.co.uk/scuttle-panels/3642-edge-trim-rubber-black.html?search_query=scuttle&results=19

 

Photo of the edge trim installed

 

images?q=tbn%3AANd9GcS9ePc8l0dMk2UQlMIlZUZdMYncp61mN4xr82-4A-iuCK7Tj9_U

 

 

Edge trim on my 2010 silver CSR

 

2h1N3oy.jpg

 

 

My 420R dash without the edge trim installed

 

bJgfVyb.jpg

 

If you want me to read the words stop putting in pictures of sexy cars and videos of beautiful racetracks!

 

Now I want a CSR too.

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Hi Greg, Thought I'd chime in with a suggestion. I had the underside of my rear fenders and cycle wings sprayed with bedliner material before I installed them. I figured it would help with any stone or rock chips flying up from the tires and chipping or cracking the fenders. My local bedliner guy did them no problem. I had him leave spots on the fronts bare where you glue them to the braces. Just a thought.:cheers:

IMAG1174.jpg

IMAG1176.jpg

Edited by Lucky-7
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Would someone mind posting a picture of their washer bottle? The manual states that the bottle needs to be installed prior to the engine, but it looks to me like the tubing and electrical terminate in the boot not the engine compartment. However, I don't see any mount point for the bottle in the boot.

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Would someone mind posting a picture of their washer bottle? The manual states that the bottle needs to be installed prior to the engine, but it looks to me like the tubing and electrical terminate in the boot not the engine compartment. However, I don't see any mount point for the bottle in the boot.

 

Greg - See if this helps you at all: https://www.purplemeanie.co.uk/index.php/2017/08/25/email-4-washer-bottle-in-the-boot/

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It goes in the boot. Don't worry about it for now. I was confused about it also but then I saw the tubing running to the boot. Those drawing's are a hoot! Wait til you have to figure out the carpet set for the boot. LOL

 

There should be a brass colored metal bracket that the bottle slides and locks into. Then you're supposed to figure out where you want to screw it into. Picking's are mighty slim unless you want screws poking through the side of the car... LOL

 

I'll get a pic on how I mounted mine... it's up on the lift with another car under it, but the weather is breaking and it's time to get them rolling.

 

Carry on, I'll get a pic later today.

Edited by Lucky-7
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