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My 1995 Caterham S3 X-Flow Emotional Support Vehicle "Beater" refresh and other journeys down the rabbit hole


IamScotticus

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One thing I really don't like about the FIA roll bar, is the FIA roll bar.

I mean, for a road car, its a bit bit much, the angle and all.

I don't intend to race, and I understand its a valuable thing, with Petty strut and all, but, I would prefer more of a DeDion style.  There never were many options for live axles, the dune buggy and the FIA.  Its when the metric chassis came that the roll bar options opened up.

So what I wish to propose to the forum is 1, a trade for something else, or 2, have welder chop and fab from the FIA?

The option I really like is have a jig made and fab up a new bar from scratch.  I would have to farm that out to someone I can trust.  

Any ideas?

 

Edited by IamScotticus
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Most of my time has been going through my parts, sorting out the T9 (34mm shaft.  yes, size does matter) and other bits from Burton.   Of course I neglected to get any clutch release bearings.

I just have the rusty off-center one.

I have a Harley Sportster Trike in the way that decided to not start recently.  Thats a project in the way.

The only 7 progress is making hanging storage for the nose and bonnet, a huge improvement.  Since my garage faces the street, everyone gets to ogle.

 

20220306_231742.jpg

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A lot of you guys are doctors, lawyers,  businessmen, etc.  enjoying the fruits of your labors, as you should.  I pretty much wandered for a while until I luckily found a traveling gig that dumped a lot of money in my lap and after two years of that I had the ability to buy a Seven.  I did and then I was broke again. 

I've been through a lot of things in the last 15 years, hurricanes,  costly marriages, and other stupid stuff, but I always held on to the seven awaiting better days. 

So, although the following current state of things may not be all that impressive to many, its a big deal personally that took a long time to achieve.  And I pray it stays this way for a while. 

Gentlemen,  I present a Seven in a garage....Where I live.

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No, Im not going to show it off now, its a basket case!  All the wings are off.

All built up she is this spec:

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But with an FIA bar, which I detest.

Edited by IamScotticus
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3 hours ago, IamScotticus said:

A lot of you guys are doctors, lawyers,  businessmen, etc.  enjoying the fruits of your labors, as you should.  I pretty much wandered for a while until I luckily found a traveling gig that dumped a lot of money in my lap and after two years of that I had the ability to buy a Seven.  I did and then I was broke again. 

I've been through a lot of things in the last 15 years, hurricanes,  costly marriages, and other stupid stuff, but I always held on to the seven awaiting better days. 

So, although the following current state of things may not be all that impressive to many, its a big deal personally that took a long time to achieve.  And I pray it stays this way for a while. 

Gentlemen,  I present a Seven in a garage....Where I live.

20220218_181008.thumb.jpg.0638c9980ac94e52a1f957d4e51c30c7.jpg

No, Im not going to show it off now, its a basket case!  All the wings are off.

All built up she is this spec:

20210416_221410.thumb.jpg.873e3ed3f9e7f412a6255172e0875598.jpg

But with an FIA bar, which I detest.

 

Hear hear. I ended up with finding my 7 at the right time in my life but it was certainly more of a financial stretch than a lot of others. Not a big deal as it's not a competition but it's easy to feel out of your element at something like a track day. At the end of the day we are all united in the fact that we love a dangerous, visceral, basic old roadster. 

 

Why the hate for the FIA bar? 

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2 hours ago, Vovchandr said:

Why the hate for the FIA bar? 

I an primarily a road blatter, living the romantic fantasy that this is somehow a sensible road car, if a road car at all.  So, tracking is not my goal.  Making a better absurd grocery getter, is.

Therefore,  I aim for two goals, authenticity to the road spec,  and good looks.  I think the fact that the Seven is a pretty little thing is most of its charm, as evidenced by the drooling and gushing you get from the admirers, everywhere.  You know someone did something right.  Every little detail of my car needs to live up to that standard.  A hard thing to keep up with, know.

Then there's my issue with the FIA.  Its functional,  but not minimalist.   The form dominates too much of the car.  And a full roll cage even more so.  This is where the purists and the engineers part, form or function.  Ive seen several ways the engineer will butcher a Seven's good looks with his idea of an improvement.  To him, the seven is just a race weapon to get him another trophy.  There's nothing wrong with that. Nearn required his employees to have track time.

The FIA bar isn't the worst example of bad taste,  but its very clear it is a racing item and you're going to ring your bell on it if you're not careful or not wearing a helmet. 

For the pretty road car, the Dedion roll bar is what Im after.  Cat never bothered to make it for the live axle cars.

Cat made it for the 160, but it won't fit my 96 LA.

20220310_233529.jpg.0742e20a636fbc5c277c9328aeca5b68.jpg

Edited by IamScotticus
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10 hours ago, IamScotticus said:

I an primarily a road blatter, living the romantic fantasy that this is somehow a sensible road car, if a road car at all.  So, tracking is not my goal.  Making a better absurd grocery getter, is.

Therefore,  I aim for two goals, authenticity to the road spec,  and good looks.  I think the fact that the Seven is a pretty little thing is most of its charm, as evidenced by the drooling and gushing you get from the admirers, everywhere.  You know someone did something right.  Every little detail of my car needs to live up to that standard.  A hard thing to keep up with, know.

Then there's my issue with the FIA.  Its functional,  but not minimalist.   The form dominates too much of the car.  And a full roll cage even more so.  This is where the purists and the engineers part, form or function.  Ive seen several ways the engineer will butcher a Seven's good looks with his idea of an improvement.  To him, the seven is just a race weapon to get him another trophy.  There's nothing wrong with that. Nearn required his employees to have track time.

The FIA bar isn't the worst example of bad taste,  but its very clear it is a racing item and you're going to ring your bell on it if you're not careful or not wearing a helmet. 

For the pretty road car, the Dedion roll bar is what Im after.  Cat never bothered to make it for the live axle cars.

Cat made it for the 160, but it won't fit my 96 LA.

20220310_233529.jpg.0742e20a636fbc5c277c9328aeca5b68.jpg

 

I didn't like the FIA bar but for different reasons. I didn't like the asymmetry or the fact the side bars were vertical and not sloped inward towards the center  so I got the double diagonal instead. 

 

If removing it is your crux and replacement is not available seems simple enough to a metal fabricators to delete it and to get it repower coated. 

Edited by Vovchandr
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1 hour ago, Vovchandr said:

If removing it is your crux and replacement is not available seems simple enough to a metal fabricators to delete it and to get it repower coated. 

I can remove it, I can run without it...

I can have a fab man weld up a new one built on a jig based on the FIA.

Black is the spec. 

I dislike powder coating too, for these applications.  POR15 or equivalent. 

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Here is a Xflow head Ive had sitting around for 15 years.  

I bought it built to this spec.

About 10 years ago i gave it to a marine boat engine man to install new valve seals and whatever, which it probably didn't need.  It was all bare metal then.  The engine man painted it with a thick coat of black.  I think he knew this heads future waz to sit for the next 10 years and a coat of paint would keep the rust off.

He was very right.

 

However, as I look toward my Xflow refresh,  its possible that head might go on.

 

So, what do I have here?

 

It looks like a ported head with double springs and maybe larger valve stems.  I don't see bronze valve guides.  I dunno about that.

I do know that I don't plan on doing any cam and piston swapping so the A2 cam and standard 1600 pistons stay for now.  Are dual springs necessary?

 

In the porting, #1 and #3 exhaust broke into the head bolt holes.

Install a sleeve?

 

What else does this head need to get ready for road?

 

Of course I wouldn't put this on without cleaning it up first.  I'll give it to a shop to dip, flux and face.

 

Measurements:

intake ports: 1 3/8

intake valves: 1 5/8
exhaust ports: 1 1/8

exhaust valves: 1 3/8
valve stem tops: 5/16
weight: 35 lbs
porting incursions:
ex # 1 
ex #3 

 

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Edited by IamScotticus
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The 13" Yokos are dry rotted.

Im thinking its its about time to to do the 14" conversion. 

 

After all, 100mm PCD opens up a lot of wheel options.  Or 4.75/108mm, for some reason, which doesn't have the OEM wheel pickings,  but has been an option for certain popular Ford wheels.  Is that the Escort PCD?

Regardless,  Im stuck with the Ital axle for now.  

 

This brings me to the question of rear PCD conversion adapters...

Are they a sensible option?

I have heard of them failing on larger vehicles,  possibly due to poor installation,  but is failure less likely on a car this light?

 

Any advice on PCD adapters please!

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  • 2 weeks later...

Has anyone found an adhesive backed vinyl covering, in red, to lay over the black Caterham instrument panel?

I suppose I could order a Prisoner spare, or buy a second hand.

That is a detail for later after we get running.

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  • 1 month later...

Really good news!

Rocker cover came off, first time in 15 years, and after sitting for the last 10....

20220426_204917.thumb.jpg.9a704dd4b9405d0876edbbd17a06c3e3.jpg

 

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the #1 exhaust has been compressed for several years. I only rotated it occasionally,  with some oil in cylinders.  

Should these springs be replaced? Valves lapped?

Hell, let's just do it all with bronze valve guides!

Ill set up the go fund me account now.

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I’d run it first, adjust the tappets and go from there. A set of springs is about $150 and I’d lap the valves if you’re planning to remove the head. Time to start browsing the Burton Power website!

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On 3/28/2022 at 11:28 AM, IamScotticus said:

Has anyone found an adhesive backed vinyl covering, in red, to lay over the black Caterham instrument panel?

I suppose I could order a Prisoner spare, or buy a second hand.

That is a detail for later after we get running.

A good quality urethane vinyl, 3m spray adhesive, exacto blade the openings in an X pattern and push the "fingers" through the holes, old-school smelly weatherstripping adhesive in a brush top can to glue the fingers down on the back side. Could be smooth or a pattern. Care for more emu? Gator? carbon?

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There is no blanket answer on adapters except that they add unsprung weight (on top of the bigger wheels and tires), increase the scrub radius (a minimum thickness is necessary for strength and to clear the original studs), can increase radial runout if not carefully installed (wheel spinning off-center). The design details and installation are important.

I'd just replace the 13 inch wheels for bolt-on 14x6.5 with 185-60-14 tires after it is running, charging, etc. Tires have a shelf life even when no cracks are visible.

I would expect your car to have 4x108 all around.

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Thanks, MV8.

 

I intend to keep the same overall diameter of a 185/70 R 13 with a 14" wheel, if I can find a Morris 4.75 PCD and matching hub and offsets.  I need 5 inches ground clearance.

And then, I have to like the spoke design.

Adapting to 100 or 108 PCD would open up so many more options. 

My Yokos don't have DOT date codes, but I put them on in 07.

They didn't get much use. Id trust them up to 30-40mph, but no more, not for long.

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Imho, the 13s are best for unsprung weight but I understand the appeal. Increasing rim size, tire width, or decreasing aspect ratio increases unsprung weight.

If the yokos are stamped DOT legal and the end of the code is three letters instead of four, then the tires are at least 22 years old now and at least seven years old when installed. Not unheard of for a tire shop to put on new old tires. Customers don't normally look at them. I sold tires and parts at Pep Boys in high school a few decades ago. I'd put a cheapo touring tire on but put the white wall on the inside unless you want to be emulate Balchowsky's old Yeller. Fun to drift around on those.

https://m.roadkillcustoms.com/the-junkyard-racer-that-inspired-the-shelby-cobra/

I manually change my tires and use an Italian, track side spin balancer designed for mounting on the back of a truck. I can use the internal motor or just spin it by hand to the required rpm. Usually I can take the old tires back to the seller for dumping for a fee or make use of my counties annual recycling day to drop off up to 10 or so.   

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MV,

I agree completely on the weight issue.  When I had a set of Panas unshod recently, I was quite surprised at the weight of supposedly light weight ali rims.  I definitely don't want to go heavier.  I have some ali hubs to go on.  I need new races.

 

My primary motivation for 14s is the diminutive selection of 13" rubber now.  more locally available in 14.

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