420R New Build!

[hahuang65]

I've started a timelapse playlist over on Youtube. It's got 2 versions, original length (as recorded by GoPro) and a post-process shortened length one.

 

Here they are. Feel free to follow as desired.

 

 

 

I'm also going to post my build questions here. I am asking Rich Kamp for help, and he's been enormously helpful and gracious with his time and energy, but I feel guilty pestering him about everything and so I'm hoping the 7 hive mind will help me... as you guys always have. Thank you so much in advance!

 

Here's the first question... I'm installing the steering rack. I'm assuming the pinion shaft should be on the driver side (in the manual, it's on the right hand side, but I'm guessing that's because UK is RHD). I've got mine on the left hand side, with the Caterham letter facing the back. Correct?

 

Second, should that shaft be angled upwards at all? Right now it's parallel to the Earth, as is the Caterham lettering. Seems like it should be angled, as the manual pictures it that way.

 

I've attached pictures.

[JohnCh]

The steering rack will need to be angled up slightly to create clearance between the steering shaft and alternator.  Personally, I wouldn't worry about that now and would wait until the engine is in and you're installing the shaft.  This way you can optimize the angle.  I'm looking forward to following your progress!

 

-John

[MV8]

2 hours ago, hahuang65 said:

I've started a timelapse playlist over on Youtube. It's got 2 versions, original length (as recorded by GoPro) and a post-process shortened length one.

 

Here they are. Feel free to follow as desired.

 

 

 

I'm also going to post my build questions here. I am asking Rich Kamp for help, and he's been enormously helpful and gracious with his time and energy, but I feel guilty pestering him about everything and so I'm hoping the 7 hive mind will help me... as you guys always have. Thank you so much in advance!

 

Here's the first question... I'm installing the steering rack. I'm assuming the pinion shaft should be on the driver side (in the manual, it's on the right hand side, but I'm guessing that's because UK is RHD). I've got mine on the left hand side, with the Caterham letter facing the back. Correct?

 

Second, should that shaft be angled upwards at all? Right now it's parallel to the Earth, as is the Caterham lettering. Seems like it should be angled, as the manual pictures it that way.

 

I've attached pictures.

When rotating the pinion/steering wheel cw,  if the rack/tie rods move to the right, then it is mounted right side up.

[hahuang65]

New question... for those of you who retro-fitted new LED headlights.

 

I've opened up the bowl and have the 3 prong, as well as two extra wires: black going to ground, and red for supposedly parking light (I pulled it off the bulb for the parking light).

The new LED plugs directly into the 3 prong, but have an extra green and yellow wire.

 

According to the manual, the yellow is for turn signal, and the green is to power the DRLs.

I don't care as much about the turning, but would LOVE DRLs.

 

The questions are

1) Can I wire the green wire to the red wire in the bowl, and tie that red wire to something else (instead of parking) to power the DRL? I read somewhere about a side light, but not sure what that means, and whether there's a better place.

 

2) Can I wire the yellow and just tie into the wire at the turn signal light, or would that be ill-advised?

[JohnCh]

Are these the factory LEDs or another brand?  

 

Side light is British for parking light. For my standalone DRLs, I used a normally closed relay that feeds the DRLs from a switched 12v+ and powered the coil from the sidelights so that when they are on (including when the headlights are on) the relay turns off the DRLs. I did this during a major scuttle-off rewiring project so can't tell you exactly where to splice into those wires. I would repurpose the red wire as you describe provided there is no side light functionality in the new LED. For the turn signal, I'd run a new wire back into the body and splice into the turn signal wire there to keep things clean. I'd also wire everything temporarily to ensure things works as expected before cutting anything. 

[hahuang65]

They're another brand: https://www.amazon.com/gp/product/B07TFJCLR9

 

Thanks for the explain on sidelights vs parking lights.

 

If I'm understanding you correctly, you've wired your DRLs to the parking light, but that needs to be switched on/off manually? I'm assuming that since they're parking lights, they're on an always-on fuse... so I'll have to remember to flip them on and off every time?

 

Sounds like you've also got it wired so that they flip off when headlights are on? Is there any detriment to keeping them on while headlights are on? Trying to way the balance between extra wiring complexity and operation.

 

Finally, since I no longer have a tail off the new LEDs that require ground... I should be able to just re-purpose the wire to ground in the headlights for the turn signal (provided it's even long enough). I know it's not best practices regarding wire coloring and stuff, but I'm unlikely to take the headlights apart anytime soon.

 

Thanks again for the feedback!

[JohnCh]

42 minutes ago, hahuang65 said:

If I'm understanding you correctly, you've wired your DRLs to the parking light, but that needs to be switched on/off manually? I'm assuming that since they're parking lights, they're on an always-on fuse... so I'll have to remember to flip them on and off every time?

 

Sounds like you've also got it wired so that they flip off when headlights are on? Is there any detriment to keeping them on while headlights are on? Trying to way the balance between extra wiring complexity and operation.

 

The relay is set up so that when the ignition is on, the DRL gets power and turns on.  When the headlights are turned to position 1 (side lights only) or 2 (side lights + headlights) the relay changes from closed to open and turns off the DRLs.  This is how many (most?) modern cars are set up.  I seem to recall Canada even requires this functionality in new cars.  The rationale for turning off the DRLs with the headlights is to avoid blinding someone at night.  In your case, with the DRL in the headlight housing, if they are sufficiently bright to be effective in the daylight, they are probably adding enough output to your low beams to blind, or at least annoy, an oncoming driver.  

[hahuang65]

Where is the relay set up? Do I need to worry about this now, when I'm assembling and mounting the headlights, or will this just be a future task, and I just need to label the wires coming out of the headlight assembly for now?

Where would I get such a relay?

[JohnCh]

What I did assumes you will find the correct wires, a suitable mounting place for the relay, and then make all the connections. I did a major rewire of my dash loom so where I placed the relay won't be applicable to your car. If you aren't comfortable with automotive wiring, then this might not be the best thing to undertake. It would be a fiddly job with the scuttle in place and requires you to trace and confirm wires to ensure you have the right ones. That said, I often do things that I have no right doing, and I haven't killed myself...yet.  

 

If you aren't familiar with how a standard 4 or 5 pole automotive relay works, it's worthwhile doing a quick search.  There are a number of youtube videos that dig into it and make it clear. I wired mine with a standard 4-pole normally closed automotive relay available at any auto parts store or Amazon.  It's nothing special. You could also do it with a 5 pole (change-over) relay.  As you watch the videos, remember that the coil is operated by the side lights, and it should make sense.  In my case pins are as follows

 

30 - switched 12v+ (controlled by ignition key)

87 - wire to DRL 12v+

86 - sidelight 12v+

85 - ground

 

Because the relay is normally closed rather than normally open, power flows between 30 and 87 to the DRLs when the ignition is on.  When the headlights are switched to position 1 or 2, power to the sidelight operates the coil and breaks the connection between 30 and 87 and the DRLs switch off.

 

You certainly don't need to do this now, but you don't want to connect the red and green wires in the headlight bowl unless you cut the red wire where you would wire in the relay.  Otherwise, the DRL will come on with your headlights.  

[fotsyr]

I think you forgot to install the headlight brackets

[hahuang65]

15 hours ago, fotsyr said:

I think you forgot to install the headlight brackets

What makes you say that? I believe I have them installed...

[KnifeySpoony]

The bracket is held on by the upper control arm bolt;

 

[hahuang65]

1 minute ago, KnifeySpoony said:

The bracket is held on by the upper control arm bolt;

 

Yup I've got them installed. Wonder what made @fotsyrsay what he said...

[fotsyr]

Look at first video.

[hahuang65]

Ah yeah. I didn't know then. I installed it in the 2nd or 3rd video.

[slowdude]

Regarding DRLs.

 

My headlight switch has a mid setting which is headlights and taillights.

 

I use it as a drl.

 

As John has mentioned, you will need to run a switch, with a relay on a separate 12v power circuit.

 

They're pretty bare bones cars, so any asks like this will always be a bit of a tweak and test mentality.