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Caterham 160 Build Blog


700newtons

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I ordered my 160 in April 2014. Here is my blog. I hope it maybe useful and interesting to others.

Caterham 160  Expected delivery November 2014.
Full Screen and weather equipment, carpets, lowered floors, push button start, leather seats, Momo steering wheel, heater, Race 4pt harness, Track day roll bar.
Ballistic orange

The lowered floor provides the driver with a clearer view and the 4pt harness and track day roll bar are for improved safety. I understand that access the Lotus 7 club track days is only possible with a track day roll bar too.

Why did I go for a 160? I definitely wanted to build my own car, I was impressed with my test drive, reviews and friends were very positive about it, there are significant savings over a Roadsport and it can be driven to capacity at road legal speeds.

Tools and Equipment (so far!)

Strongman Tools
Trolley jack and axle stands (discount with L7club membership)

Halfords
Socket set, prof torque wrench 8-60Nm, prof torque wrench 60-300Nm. Birzman deadblow hammer

Maplin
Garage alarm

279 Comments


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Hi

I'm sure your blog will be very useful to me. My 160 kit arrives in March. I think there are 3 of us on here awaiting a 160: you, me and Michael Stallard (also has a blog).

At the moment I'm reading the manual carefully. Also reading the Westfield manual, which is much clearer in lots of ways - better diagrams, better photos, lots of general workshop hints.

I look forward to following your progress!

Ned

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Great! Now there are three people I can email when I am fretting and swearing over mine. I'm not massively impressed by the manual. Nowhere near as clear as the Westfield equivalent (though that's a much more complex build, admittedly).

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I agree with you Ned. When I was purchasing my kit at Crawley in April a 'young thruster' on the sales staff told me he was rewriting the 160 manual to make it more user friendly and I was hoping that my kit would be supplied with this new manual rather than the one on the Caterhan website. Maybe it's time we started asking the question.  

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I might have misled with my last comment. I see that in the account holder downloads on the Caterham website there is now a C160 Assembly Guide dated Aug 14 (with a list of amendments dated 20 Aug). This must be the version that I was refering too and although difficult to see the changes v the Dec 13 version, it seems to be better.  

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Ah, I hadn't spotted the update to the manuals online. It looks largely the same, though some of the photos are a bit clearer (albeit with some of the labels now dropped off the photos).  

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Delivery of my kit delayed 3 weeks - no idea why. However, just bought a number plate 'C16 OPM'. I reckon if I get the 6 and O as close as pos and leave a gap between the O and P (within legal allowances) it will look OK as 'C16O PM'. £399 from DVLA, who are definitely the cheapest unless you want something really exotic.  

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  • Leadership Team

Hi folks,

thanks for for your replies. It is good to know that there are at least 4 of us. Apologies for the delay its my reply. I didn't realise I was getting comments on my blog!

looks like I'm the guinea pig then...

I think my first job is to wax the car, Dimitrol the inside and cover the paintwork for protection.

Simon

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Hi. Add another 160 'owner' waiting for his kit (mid-Nov for me) and it's great that there is going to be a '160 Blog' which I shall follow with much interest and constribute whenever possible. Peter and Angie Miles based near Fareham, Hants

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C160 kit delivery confirmed as 16 Dec - some crimble pressie this is going to be. Simon - have you any 160 'delivery day' tips I should look out for? Did you get your IVA pack and steering rod ends?  

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  • Leadership Team

Peter,

I rang up Caterham and got an IVA pack sent through the next day. I also recently received the RH lower wishbone via courier. The steering rod ends were attached to the brakes ( doh, that was my bad). I'm now on the hunt for some 10mm grommets for the lighting brackets.

Generally though, everything is neat and well labelled. As I go I'm carefully ticking off every paragraph of the manual.

I have no particular tips for delivery day. Get your axle stands roughly in place and place old squares of carpet or cardboard on top. The delivery bloke is very helpful. Oh, and the wheels will be coming later, I expect.

I look forward to hearing more.

Simon

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Ned - you might be interested; Lloyd and Whyte are specialist Caterham insurers and do a separate policy whilst the car is being built @ £78 for a year. This can then be converted into a normal road going policy.   

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  • Leadership Team

Peter,

That is interesting to know (but obviously to late for me).

just a few days to go for you then....

Simon

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Thanks for the tip, Peter. I rang round a few insurers, both for build-up and normal car insurance. Quotes varied wildly (Adrian Flux were over £500!). I shall try Lloyd and White before D-Day!

With both of you progressing ahead of me, I feel a warm glow of confidence that you'll troubleshoot it all nicely ;-)

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  • Leadership Team

It might depend on who you speak to at Adrian Flux. I rang up twice and the second quote (with Trinity Lane as insurer rather than Equity Red star) was cheaper and more gave much better flexibility with the build. (£250 for 3000 miles) but you might do better with Peter's separate build insurance and then insure for road use.

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Simon. Advice in due course please. Are you fitting/have you had fitted - a 12v socket (for sat nav, tyre pump etc). If so, I would appreciate a tip on what sort to bought, where you/caterham sited it and into where you/caterham wire it in relation to the wiring diag in the build manual.   

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  • Leadership Team

Hello Peter,

I didn't ask for a 12v socket. I can't really help with this one. If you would like a photo of the dash or something, let me know.

Simon

 

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I think there are a ton of posts about this in blatchat - if you can find them... Also there's a link here about how to do this.

I'm going to get a 12v cig lighter to place in the dash (to charge the battery, via an always-on space on the fuse box the other side of the scuttle), and then a weatherproof (capped) 12v-sized USB charger to fit between the seats on the bulkhead (for phones, cameras etc) with a fused wire going along the inside of the tunnel up into the boot.

You can get them from Maplin or a marine chandlers for less than £10. Or on Amazon for less than a fiver.

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Unfortunately the 'weight challenged lady' didn't sing for me today because the left and right hand of Caterham failed to co-ordinate when I was given a delivery date of today. Delivery is now Thurs 18th. 

Simon - when you said you were having difficulty getting the exact Shell lubricants recommended for the C160 I thought you were joking but some 'surfing' shows that there is a problem - or am I being thick. Would appreciate some advice when you finally get yours delivered. 

 

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  • Leadership Team

Oh no! Actually when mine was delivered, the delivery driver arrived an hour early and had to wait. I told the sales guys that I couldn't be in before 2pm but the message fell through. The driver was OK about it though.

If you look on the Caterham website, it says that the 160 comes with all fluids. I need to put my gearbox oil in now, so I could really do with it. I'll ring them up shortly.

I think that the oil is available, but just in large quantities, as far as I could see.

160 is good to build by the way (although I have to read and reread the instructions). A lot of he stuff that I would potentially really mess up has been neatly done already.

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Having re-read the latest spec I see what you mean re the 'first fill liquids' sub note to the standard kit price. I also see that I might be getting a push button start as standard - I'm sure that was an extra when I ordered the car. 

Ned - to avoid the delivery confusion experienced by Simon and I, nearer the date given by Crawley (Sales), recommend you call Dartford (Production) and ask for Sharon........she runs the delivery drivers schedule!

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  • Leadership Team

Hello Peter,

i ordered a push button start for mine  - it doesn't look like a freebie. Maybe you just got lucky. However, my car appeared with a aero filler. I think that was an option which I didn't ask for. However, it seems a standard option now.

i left a message at Caterham regarding the firt fill pack. I could do with it...

Good of luck for tomorrow. If you have the same shortages as me you,will be missing wheels, the rear axle casing and the fluids.

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Arrived safely at last. Start button and Aero filler cap fitted. Some oils (just 5 litres of Shell Engine oil and some clutch/brake fluid) no gearbox or diff oil. I wonder if we can use Shell Spirax S4 AT 80/90 in the gearbox, there seems to plenty of that around in small quantities. No wheels and (annoyingly after Simon's experience) no IVA bag........helpful Derek at Dartford already on the case!

First job done, close look at underside of metal sprayed chassis bars and Hammerite those that are chipped scratched ......quite a few I might add.

If I could find out how to get photo's into this 'blog spot' I could show you the car - any advice on this would be much appreciated as copoy and paste doesn't seem to work..  

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Congrats Peter on your new arrival!

Shame to hear about the frame, and having to Hammerite it. Not great. If the chassis is on axle stands, did you creep underneath to do this? Just wondering how heavy the chassis is and whether it can be easily supported upside down first (like Westfields do I think).

For pics, hit the pic button on the toolbar above the message (13th one along), then hit 'Browse Server'. Once you're here, you can upload pics from your hard drive to your space on the Blatchat server. And then select the photo you want, and it should appear in your draft message. The format/size/shape can look a bit weird, but if you hit 'Preview' below, it should sort itself out and you can then Post.

Hope this helps, and good luck.

Ned

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  • Leadership Team

Great news! Looking forward to see the pictures.

You must be missing the rear axle case too. I contacted Caterham today; they are on route from Japan.

Apart from the shortages the kit is pretty good isn't it? And everything fits snugly. Occasionally, I think something is missing but I just haven't quite realised what I am looking for.

i think I might have used up my IVA rubber on my front suspension holes. I have seen this on some cars but not on others. You might want to pause before copying me.

I brushed on Hammerite stone guard on the underside of the wings today (to reduce stone damage from below). It has a pretty strong solvent that has a negative effect of it is splashed on the paint on top. I got away with it though.

NB The way I get pictures inserted is go to 'My profile' then 'file browser'. I upload the pictures then link the to the blog.

Simon

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