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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 all I've put my mirrors in the same location, I'm not sure they would be usable in the higher location.  Anyhow they are coming off as soon as the IVA is complete because with the stalks the doors do not open fully 

martin 

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  • Leadership Team

A frustrating afternoon...

the replacement ECU arrived and I fitted it. However, in doing so I managed to break the bottom ECU holding bolts with overkeen tightening (dammit). Anyway, I have replaced them with M5 bolts so no big issues - just annoyance.

The car still won't start; the ECU doesn't seem to be the problem. I'm not sure what is though??

The engine does produce a high pitched whining noise on key position 2. See here: http://www.youtube.com/watch?v=8wWwjWJwPjY

I have emailed Derek.

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I ordered one from Amazon, but then I learnt from Caterham that it won't work (there is some kind of code), so I quickly cancelled the purchase.

it looks like it might have to go for the PBC unstarted (sadly).

Simon

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Sorry to hear of your continuing misfortune Simon. I have just emailed Derek re starting, as although I've had mine going 3 or 4 times there are occasions when it just does not want to know. When this happens I hear a click from one of the vacumn/electrical 'gizmos' on the front of the engine. The hose connections to these things seem to go all over the place; into the turbo dump and the fuel intake area and I'm wondering whether I might have incorrectly connected those that you do in the build meaning a residual vacumn is holding off a 'go' permit in the ECU. Pure speculation of course, but I have asked for better piccies and details than there is in the manual anyway.  

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Yes good idea - I did have a good look using Martin's pics. However, the vacuum hoses are quite complex and it is hard to see.

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Car on wheels and started 1st time. I drove it up and down the drive so car finished except for stickers and IVA 'titillations'. Unfortunately after 2 other perfect consecutive starts it didn't want to know again, doesn't even try to start so there must be an electrical 'stop' occuring in there somewhere......very annoying. But I reckon it will go again tomorrow. Luckily PBC in 2 weeks and they can solve it. So plenty of time to polish it and having driven it I'm well chuffed! Mrs M already asking what I'm going to do to occupy myself next Winter....I wonder if I could afford a Supersport!  

FinishedCar-Small-26Mar15.jpg.3bd31c6622f5a866ebe9fbcbccddb34b.jpg

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It looks superb.

My car will go off for the PBC without starting unfortunately, but there it is.

I was thinking of my next project too... 

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Bravo, Peter! It looks very fine all in white. And hopefully Caterham can figure out why the starting is so erratic on the new ones.

Roll on Monday, and the arrival of mine...

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Hi all, mine is finished too and going for its PBC on the 7th of April.  Mine has started quite a few times now so maybe I'm just lucky.  I've also taken it for a spin down our road, nice to know I've bolted the mechanicals correctly because it all seemed to work up to 2nd gear. I'm still waiting for my IVA arrangements, seems to be taking an age

regards

Martin

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Wonder how they got through IVA with no trim on the edges of the reverse and rear fog light!

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Apparently for the gillingham IVA test centre you do not need trim on those two bits anymore

martin 

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Went for the PBC today; some washers where they shouldn't be and some not where they should - all easily solvable. Spring washers under the engine bracket bolts is not a problem. Other points of note; if you have a number beginning with 'e' on the riveted plate under the brake fluid reservoir (like me!) you have a C165 (Europe) left hand drive plate that will not get through a UK IVA. So old plate drilled off and I have to rivet on another one when it arrives from Dartford. 

Also, they remove the top steering column and wheel and put in a temp Caterham Momo that will pass IVA. And I have to fit my own after the IVA and return the 'IVA wheel'..........how daft is that! However, must say the after sales team at Crawley were excellent.

Agree Martin; not one car at Crawley has edging around the fog and reverse...............so why does the manual say do it?

So onwards and upwards to IVA next Thursday at Southampton 

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Hi all I took my car up on Tuesday for the PBC today but no contact from Crawley so I will ring them tomorrow to find out if I have the same fun and games with the IVA. My IVA is on the 24/4 so still a few weeks to go. The fog lamp point was a specific question I asked Derek who confirmed that the trim wasnt needed

martin 

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Keep us posted!

I'm dropping my car off on Saturday (after is gets some 'premier paint guard' protection on the rear mud guards).

Interstingly I had an email from VOSA today asking for the designed gross weight (which I didn't put on the IVA form. Apparently this should be 733kg or whatever is on the plate on the car.)

If you look at Martin's photos, the orange and blue 160s have different gross weights/axle loads

This one is different to this one

However, I think that the gross weight is supposed to be 733kg (?)

maybe this is just pedantry.

Simon

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I put 733 kg which is the number on the plate, also confirmed in the manual . I had a small scare on the front wing when the IVA states that the wing has to be over the front of the wheel . I read this as the tyre which my wing is most definitely not, but of course it is over the wheel when you look at the wheel itself imagining that the tyre is not on it, phew!  What a lot of faff this IVA thingy is with a lot of it not seemingly making much common sense!

martin

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Simon - your phots are interesting and worrying! The blue car has the number chain beginning with 'e' that i mentioned and shows a combined axle weight of 860kg; which is as per my IVA application, as written for me by Caterham. However, my plate (now my 'old' plate') reads 733kg so I wonder what my new plate will say. If it doesn't match the IVA application I reckon my chances of passing are currently zilch!   

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I did wonder whether to post those photos (it may not matter).

I copied the IVA forms that you kindly forwarded to me but VOSA queried the missing gross weight. I had an email from them today saying that they are now OK with my corrected axle weights and gross weight.

it is probably best to check with Derek.

Simon

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Seems like I am using the IVA steering column as well after you Peter. It's getting handed around like some used newspaper so I have to fit it for the test and then put my old one back on after the test and return it to Caterham. Have you ever heard of such bureaucracy gone mad!

Martin

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Simon - I have passed on my concerns to Paul at Crawley and Derek at Dartford. My hope is that para 4 on the IVA form is 'ORIGINAL Design Laden Weight' and the weight on the plate is the ACTUAL Laden Weight whch, if is below the design, is OK.  

Martin - as you are next with the steering wheel perhaps we can meet halfway between Fareham and (if my memory serves me well) Wokingham rather than me posting what will be a very awkward shape back to Crawley.  

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Other snippets from my IVA check at Crawley:

1. Take out washers under studs holding fan to rad (that manual say put in) so studs 'show' through the nyloc

2. Put washers either side of the rear brake thro bulkhead connector (the manual say use a plain nut). This is a pain as it means re bleeding the brakes.

3. Radius (half grommets) on top surface of door hinges (windscreen fittings) on the side that are flush fitting (for when doors are off).

4. Trim on the exhaust brackets and front edge of the heat shield.

Other: I have part labelled my dash on safety items (lights, horn, indicators). Also labelled to show rear fog switch is a 'Press On' not a click type. Ken the Tester didn't know about it being a (new) self cancelling switch and at first thought it would fail IVA - so better safe than sorry in case Inspectors think the same. I have put heat shrink over the long thread sticking out the bottom of the uprights. I also shortened the long thread on the exhaust clamp (apparently the exhaust is a touchy area for IVA inspectors - no pun intended. They were concerned that my car didn't seem to have an adequate centering action when hands off the steering wheel. They eased a screw in the top of the rack which improved things and advised 'take a long run to the IVA centre to work the front suspension'! 

 

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Hi Peter, I've just had my PBC check with Caterham and have had very similar things as you.  I've decided to leave the car up at Crawley and let them do the bits it needs and then take the car directly to Gillingham for the test from there.  So I'm sorry but I can't meet to collect the IVA wheel and it will need to go back to Crawley, sorry about that.

Regards

Martin

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Thanks for the PBC comments Peter, interesting.

I managed to sort some of them before I took the car off today. However, I didn't have time to sort others.

Simon

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