Great IT advice Ned. For info on pic: yes, I made my own axle stands so the car sits higher than normal (I am of 'mature age so want to save the old back!), the white board is a left over bit of hardboard painted to reflect a bit more light on things and the anti-fatigue mats are (were) on offer at £10 a set in Halfords. The added height allows me to get underneath and also stow many of the boxes there - but means I have had to buy a more expensive trolley jack to get it back down! I also made myself an engine 'dolly' so it can be stowed out of the way, moved around to fit the gearbox and brought to the front at fitting time. I wouldn't like to support the chassis upside down and it's a lot heavier than I expected.

So I'm off and running, but my progress will be slower than Simon's as this is a 'retirement job' that Mrs M said I needed (must get!) to keep me occupied when I can't play golf. 

Very tidy looking garage, Peter! And thanks for the update and advice on the frame. 

How nice that Mrs M is actively encouraging you to build cars! I was lucky like that too.

Funeral I'm afraid......................a timely reminder as to why you just have to get on and do it! Then preservation and masking up.

Simon - question; the gaiters in the IVA pack that look like they should fit the trackrod ends are closed at the narrow end. Did you drill through or are they for somewhere else?

Cheers Simon - ooops, read the instructions, lesson learnt.  

I actually ended up doing one side of IVA rubbers around the suspension holes late today - not the easiest of jobs. How they expect you to do it after fitting the suspension I don't know. I glued them at various points with superglue.

Advice to upcoming builders; google HAFIX Industrial Products, they sell an industrial superglue in small sizes (and glue remover!) online for £10 a pot. I first saw it at a caravan show years ago, you keep it in the fridge and it last for ages, sticks anything to anything in secs, with the smallest of drops.    

I'm expecting an oil delivery tomorrow; I suspect it will be the same as yours so I will be v interested to see the outcome of your query. Mineral oil sounds a bit 'last decade' doesn't it!

Incidentally I have clarified with Derek re the '7' on the nose cone; the 1st line of the IVA advice says it should be on the inside of the grill but it comes on the outside. Derek said they recently redesigned the grill to pass IVA - one to tick off then! Derek has also promised me some touch up paint in the new year - one to ask for unless you have already.  

I see what you mean re front lights, indicators, grommets and difficulties, I bought a pack of assorted grommets from eBay a few weeks ago so I have one, I haven't seen one in my kit and I agree with you, the shrouding should be more then adequate. With a grommet in place it leaves a very small hole to pass the wires through, let alone the shroud. That will be tomorrows 'persevere' job because with a grommet in the hole I can't see how you can add the lights to the bracket after the suspension has been done.   

. 

I also had a mesage re 'no oil' so at least that's cleared up.

I managed to fit a grommet on the headlamp bracket but it makes fitting it an issue as you then have to 'squeeze' the grommet quite hard to get the light bracket 'clip' to fit onto the chassis bracket and line up with the top mount holes. I ended up 'easing' the clip a bit.

Are they sending you a 'proper' grommet? If so I ask for one and pause a while for the 2nd wishbone. I found that the only way to sort out the headlight/winker combination and get the wires running correctly is on the bench and then fit the assembly as a whole.  

Grommet problem cracked; I also stuck a 1/2 grommet on where the cables some through the chassis hole into the engine compt. Yes, a half grommet is one cut in half, I'm calling it a 'Wallace'........Wallace and Grommet.....,get it, oh never mind! 

Also finished the front suspension + ARB today; for upcoming biulders, have a length of stout rope to form a 'Spanish Windless' to pull the ARB ends into the wishbone fixings.

Next I would be on to engine and gearbox but discovered, when mustering the parts, that I did not have a gearbox extension and Dartford is closed until Jan 5th. Ah well, at least Mrs M will get a bit more attention for a week. 

Hi Simon. 

Missing bits are a problem aren't they; whilst 'browsing' I found out today that I did not get a lower steering column, and the washer jet fitting did not have a retaining nut - the latter is 'smally beer' but annoying! 

Regarding wheel arch protection; I was following your lead until a friend and fellow 7 owner told me about 'sticking' the front bicycle wings rather than drilling etc.  - and then I saw that you will have to take the stone chip off to do this. So my current thoughts are white stone chip at the back and sticking thin rubber (pond liner - I have left overs!) under the front wings (leaving space for the carrier bars) and then sticking another piece of rubber across the bars to deflect stones away from them; it might also help stop the wings from flying off (as one partly did for my friend whilst doing 80 on the motorway!)  

I hadn't realized we were such 'early innovators' but it figures, as marque wide Caterham fits seem to go well (all the bits, good fastenings, well documented) but 160 bits not so. 

I have bought SS rear wing stone guards with the kit but if Premier Paint Guard are making template fits for the 160 I'm interested, particularly for the front nose cone area.

Returning to an old chestnut - I asked Derek if he had an advice re fitting a 12v socket. He said it was already wired into the loom. So if you come across a connector with Black and Purple/Red wires please let me know where, as I'm damned if I can see it..........even after 15mins upside down in the footwells! 

Which makes it odd that it costs over £100 on the order form... You can get one off eBay for about 3 quid!

I am intending to put a second one - actually with 2xUSB sockets - between the seats on the rear bulkhead.

By the way, have a look at the new R500 blog on here by Daniel. His descriptions and photographs of electrical and other tricky bits are superb.

It sounds like you're facing quite a few missing bits and pieces. It's a shame - and surely must cost Caterham a silly amount in courier bills to keep resupplying you.

Look forward to your next update though!

Ned

Hi Simon,

You are not being daft; I agree, the fan will not fit the bolts and I cannot see an adapter plate.

When my 7 owning friend came around he had a close look at the rad as it was a bit of a Caterham 'achilles heel' (he had one fail overseas and it cost a lot!). However, he was glad to see they had updated the design; perhaps they forgot to make sure the fan fixings matched.  

Sooner or later someone will tell us it's 'all part of the Caterham experience'

Peter M 

Simon - Seeing as the C160 phot at the top of this website seems to have the new rad fitted the I had another look at this. You should have 4 x right angled plastic brackets in the 'Cooling' parts bag (where the cotton reel rubbers are). They slide into 4 slots on the fan and then will line up with the rad bolts. If needs be I will post a photo here tonight.