The start of something really fun . . . .

[jfgw]

I have a QBE60G with straight cut gears in my Vauxhall 2 litre Caterham, it really is a lovely piece of engineering. The cost was approx $10k which I still wonder about, but the feeling of solid very fast changes with your foot basically flat on the floor is something else. I have no problem using it on the road, as I am used to riding sportbikes - it just takes a little forethought. It does clunk when pulling back into 1st from neutral when sat in traffic, but when someone has been staring at you and then they hear that, you can almost feel their smile turn into a grin! Heartily recommended, you will love it.

[jturrell]

I received my chassis number. The car is scheduled to be built the week of March 4-11. I was surprised to hear that there are 5 additional cars coming in the shipment from Caterham with mine. That's a lot of new sevens.

[scannon]

Between the US car magazine reviews, YouTube videos and Top Gear UK there is a lot more awareness of Se7ens than in the past.

 

I wonder if Caterham USA has a car scheduled for a Top Gear USA segment.

[Croc]

I wonder if Caterham USA has a car scheduled for a Top Gear USA segment.

 

I think they have made all episodes of the first series of Top Gear USA and no Caterham was in it (based on me being curious and researching on the internet). For the second series maybe?

 

The problem with giving it to a car show like Top Gear is whether you (Caterham USA) would trust them to give you a fair review? Westfield UK did this on a UK TV show just recently and it was a major black eye to Westfield from a biased reviewer and a poorly prepped car as read on the Westfield Sports Car Club forum postings. Top Gear UK did a similar job on Lancia Stratos kits once.

[Croc]

I was surprised to hear that there are 5 additional cars coming in the shipment from Caterham with mine. That's a lot of new sevens.

 

 

Yep I heard that when I was at Caterham UK in November. They were pretty excited about having 6 kits go out at once.

[jturrell]

The crates finally arrived. Picked everything up at British Auto Specialists in Ft. Worth yesterday. Unfortunately, I have to go out of town tomorrow, so I won't be making much progress this week. Jeff and his crew were very helpful getting everything on my trailer. Just getting organized is a fair amount of work.

 

Some surprises with the kit:

 

- The chassis was pre-insulated with heat reflecting material. I had seen this on a few recent cars in the forums, but wasn't sure if it would be included on US cars. They did a better job than I would have been able to do.

 

- I got the Ford diff. They're switching to BMW diff's, and I wasn't sure what I'd get. This should be a plate-type diff, so hopefully it doesn't really matter.

 

- I ordered a regular black Stack dash, and they gave me an R500 (white) dash. I think it looks really good, and compliments the white stripe. Feels like I got something extra.

 

- Lots of items already installed (dash, gas tank and associated hoses, wind screen, etc. Pretty happy about it all.

 

- So far, no obvious shortages. But I'm not that far into it yet.

 

Here are some pics:

 

http://i51.photobucket.com/albums/f394/jcturrell/Chassis.jpg

 

http://i51.photobucket.com/albums/f394/jcturrell/Nosecone.jpg

 

http://i51.photobucket.com/albums/f394/jcturrell/Dash.jpg

 

http://i51.photobucket.com/albums/f394/jcturrell/Tires.jpg

[MHKflyer52]

The crates finally arrived. Picked everything up at British Auto Specialists in Ft. Worth yesterday. Unfortunately, I have to go out of town tomorrow, so I won't be making much progress this week. Jeff and his crew were very helpful getting everything on my trailer. Just getting organized is a fair amount of work.

 

Some surprises with the kit:

 

- The chassis was pre-insulated with heat reflecting material. I had seen this on a few recent cars in the forums, but wasn't sure if it would be included on US cars. They did a better job than I would have been able to do.

 

- I got the Ford diff. They're switching to BMW diff's, and I wasn't sure what I'd get. This should be a plate-type diff, so hopefully it doesn't really matter.

 

- I ordered a regular black Stack dash, and they gave me an R500 (white) dash. I think it looks really good, and compliments the white stripe. Feels like I got something extra.

 

- Lots of items already installed (dash, gas tank and associated hoses, wind screen, etc. Pretty happy about it all.

 

- So far, no obvious shortages. But I'm not that far into it yet.

 

Here are some pics:

 

http://i51.photobucket.com/albums/f394/jcturrell/Chassis.jpg

 

http://i51.photobucket.com/albums/f394/jcturrell/Nosecone.jpg

 

http://i51.photobucket.com/albums/f394/jcturrell/Dash.jpg

 

http://i51.photobucket.com/albums/f394/jcturrell/Tires.jpg

 

Looks like X-MASS came early for you......very nice....hope you post more photos of the construction as you progress.

[Ian7]

" - So far, no obvious shortages. But I'm not that far into it yet. "

 

LOL (this your first do-it-yourself Caterham? HA)

[Alaskossie]

Jturrell,

 

What wheels and tires did you order? Those sure look like track-only tires.

[jturrell]

I ordered the 13" Avon ZZR's. I intend to use them on the street - not sure yet how that'll work out . . .

[Croc]

I like the color scheme. What engine spec are you putting in here? The R400 220hp duratec?

[jturrell]

The front suspension is in. Getting the anti-roll bar balls into the cups (circled in red below) made me question my sanity for a moment, but the rest was relatively straight forward.

 

http://i51.photobucket.com/albums/f394/jcturrell/Front_Suspension.jpg

 

http://i51.photobucket.com/albums/f394/jcturrell/ARB_Ball_Hell.jpg

[jturrell]

I like the color scheme. What engine spec are you putting in here? The R400 220hp duratec?

 

It's the R400 210hp. To get to 220, I'd need roller barrels. Although they get good reviews, they're expensive. Having gone crazy on the transmission, I had to draw the line somewhere, and outright power wasn't all that important to me. (yet) : )

[slngsht]

It's the R400 210hp. To get to 220, I'd need roller barrels. Although they get good reviews, they're expensive. Having gone crazy on the transmission, I had to draw the line somewhere, and outright power wasn't all that important to me. (yet) : )

Adding 10 hp at a time is over-rated anyway. When you are ready, add 50 at a time. First test drive will be much more rewarding

[Croc]

10hp is not much return for the cost of the roller barrels. Having seen what a little old crossflow seven can do in the hands of a capable driver, I think you would get more value for money out of some driver instruction.

[jturrell]

Working on the engine now. I purchased the remanufactured duratec from my local Ford dealer per Caterham USA's instruction. AER remanufactures the engines for Ford. I tried to purchase directly through them, however they'll only sell to Ford dealerships.

 

Working on the duratec is easy, assuming you have the right tools. Caterham doesn't provide any engine build instructions - here are the resources I'm using:

 

CHILTON Guide for Ford Focus (make sure it covers up to 2007)

http://www.amazon.com/Ford-Focus-through-Chiltons-Repair/dp/1563927853/ref=sr_1_2?ie=UTF8&qid=1311076325&sr=8-2

 

Two great blog entries on replacing cams & valve springs in a duratec

http://duratec.wikispaces.com/modification-cams

http://duratec.wikispaces.com/modification-valve_springs

 

Here are some tools you'll find useful:

http://massivespeedsystem.com/_massive_speed_system_/massive_absolute_timing_tool_set/mato8754/i-273565.aspx

http://www.google.com/products/catalog?hl=en&q=schley+universal+valve+spring+compressor&bav=on.2,or.r_gc.r_pw.&biw=1600&bih=719&wrapid=tljp1311077644271045&um=1&ie=UTF-8&tbm=shop&cid=15492685783458930363&sa=X&ei=IXUlToCjKMzEsQLZwJzUCw&sqi=2&ved=0CDwQ8wIwAQ#

 

You'll need an overhead valve spring compressor - a regular one won't work. I'm waiting on this right now - should arrive today. In addition, you'll want a flywheel locking mechanism. If I had any fabricating skills, I'd have just made one. It's just a little plate that keeps the flywheel/crankshaft from moving. I'm using one made for BMW's, and it works fine.

 

http://i51.photobucket.com/albums/f394/jcturrell/Engine-1.jpg

 

http://i51.photobucket.com/albums/f394/jcturrell/Cams_Out.jpg

[jturrell]

One other note - I've heard differing advice on this. Apparently you need to pressurize the cylinder with compressed air while you're replacing the valve springs. This is to prevent the valve from just falling into the cylinder when you remove the spring. Some folks I spoke with have said it'll be stiff enough, and won't just fall in. However if it does fall in, it'll be a pain to get out, so I'll be going down the pressurized route. To do this, there's an adapter you can screw into the spark plug hole and connect to your compressor. I'm hoping to replace the valve springs tonight.

[bsimon]

You can fill the combustion chamber with clothesline and rotate the crank to gently squish the clothesline against the valve heads to keep them closed for spring installation/replacement. When you're done, back off the crank and pull the line out of the chamber.

[MHKflyer52]

You can fill the combustion chamber with clothesline and rotate the crank to gently squish the clothesline against the valve heads to keep them closed for spring installation/replacement. When you're done, back off the crank and pull the line out of the chamber.

 

Now that is a good tip and one I hope to remember.

[gerald kenneth bowden]

have you seen the mag. caled europe in barns and noble in the back secton is a section on a super 7 caterhan showing the build and the story of the new oner in new york also the cost of of the complet car a very good story.