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The adventure begins....building my 420R


mdork
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Steering all sorted now. Was a bit of an RTFM moment as I'd not inserted the upper steering shaft in the correct orientation, causing the binding. All back together and torqued. On to the expansion tank next and then go for my PhD in plumbing :)

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Mega day today - finished plumbing, reinstalled plenum, installed the throttle cable, and got the airbox in. Plumbing is done apart from sorting a ground from the submarine. Seems I'm missing the right nut. My kit was also missing the 5/16" tube to connect the expansion tank breather hose but a trip to local auto parts store got me sorted. Dangerously close to first engine start. Just need to get fluids in, battery acid in + charge, and I should be ready to go. 

 

One thing that seemed too easy was the throttle cable. I've read about people needing to bend the pedal quite a bit...mine seemed to fit quite well without any bending. Probably messed it up somehow...we'll find out soon :).

 

Rear fenders are off getting PPF ... terrified to glue the fronts on .... maybe next weekend. I'm determined to finish by the end of the month though I think I've missed the window as far as Seattle weather is concerned. 

 

 

 

 

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Speaking of assembling a Se7en, I just read an article on the Lotus 7 history. They were marketed as kit cars  to avoid the draconian sales tax on new cars then in place in the UK. The catch was, to qualify for tax exemption, the kitcar had to be sold with out assembly instructions! Chapman complied: every kit came with “diassembly” instuctions, which the buyer followed in reverse order:).  Thus launching a tradition of supplying challenging assembly instructions,  a tradition that Caterham has proudly continued.

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True innovation! There have been many moments of pure mystery during the build so far. All part of the adventure. Just glad I have Bruce nearby to do a post-build check to make sure I didn't make any egregious mistakes. Will make me feel better about putting my kids in the passenger seat.

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Big milestone yesterday - first engine start went beautifully! Learned a few more lessons along the way. 
 

Planning to drill the steering wheel today. Possibly tackle the rear fenders as well. 
 


 

 

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Bruce confirmed those mystery wires connect to nothing. 
 

In other news - got the steering wheel in and adjusted. Couldn’t help but do a very slow lap of my street. She feels eager! Will be away from the car for a bit before The Big Push to complete by end of the month. 

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Yep, there's another set of unused wires on the left side of the engine near the oil filter as well. I just ziptied em somewhere out of the way.

 

Nice progress.  Everything is still fresh in my mind from my build so any other questions, ask away.

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Big day yesterday. Wings are on!! Took some courage to do the fronts but hopefully did ok. Love the new LED lights in the rear but Caterham don’t supply a grommet so will have to harvest one from the supplied set. Got the fuel filler cover and washer bottle in as well. The supplied wiring harness was too short so had to build a little jumper. Will do the repeaters today along with trimming the knee panels to fit. After that it’s off to Bruce before I can do the final few bits. Sadly the weather is horrid this weekend but hopefully will be out for a blat soon!

 

 

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Before you install the knee trim panels, if your car didn’t come with them, you should consider getting the fixed nut windscreen brackets. That way if you decide to take the screen off and put a brooklands screen or aero screen in you won’t have to drill out the rivets to get to the nuts.  
 

Nice build. BTW.  Tom 

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While waiting for a few bits needed to install my repeater lights I decided to make some simple protection for the boot skins using a roll of neoprene. May not win any design awards but I’m happy with the result :)

EC5AC7CE-2A76-4D85-9E89-FF8E6D8D8A05.jpeg

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