I think these are generic Caterham issues, so you might get some help from the general owners via BC? I've seen examples of people lending each other trailers etc.

Simon - I have a hand written (by me) copy  of the IVA Form as it was sent to me from Caterham. Give me your email address and I will send a scan. I now have an IVA date at Southampton of 16th April and waiting on a call back from 'Paul' at Caterham Aftersales Dept re a post build check. I shall trailer it up to Crawley; however I think you can hire car recovery type vehicles. You are allowed to drive it to the IVA centre - which most people recommend.  

Finished the back end today; back lights units a bit cheap and nasty but fit OK, albeit using self tappers through GRP!! Only point of note for future builders was a 'rats tail' earth wire coming from top right back of fuel tank IVA guide says 'tank must be earthed and seen to be earthed'. When asked, Derek said connect it to the nearest rear wing fixing bolt - which I have done, and wound green tape around it so it can be easily seen from below.     

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Hi All, Peter looking good, i'm awaiting the nylocs for the bottom of the upright and I still cannot upload pictures, most of mine of 2.5MB so I will have to find a way of taking less space and I cannot upload them to the server to start my blog.  Had a bit of a brain fart about the closing plate on the bell housing but figured it out in the end, I hope to get the engine/gearbox in on Monday.  Derek has been a star

Regards

Martin

I too think there is something not quite right about the clutch cable/mechanism (and I had received a replacement cable as the one supplied with the kit did not have a clevis on the end!). Investigating further I see that the Jan14 version of the manul shows a Clutch Cable Retainer clamp at Fig 54 but the Aug 14 version (which I'm working to) doesn't, nor does Fig 55 show it. I reckon the lack of the clamp on the reverse of the clutch fork is what is making it 'sloppy'. Needless to say, an email is on the way to Derek!

Re fuse box cover - haven't looked at it recently but I found a blog (might have been Andrew B's) that said it is retained by velcro (which I don't have) and does not fit like you think it should!

Got my engine, gearbox, diff, axle and props shaft in today. The diff fiiment to the axle case was a swine, I took a wee bit of the casing off with the Dremel to get it to fit!  Also some of the radius arm sleeves do not fit so I am going to have get them turned down to fit.  Also I thought I was being very clever in filling the gearbox oil in before I put the assembly in the car, not clever at all as about a litre poured out the back as the engine was being lowered. Also slightly concerned about whether the engine mount bolts need a lock washer on them or not, mine do not so I think I will leave it. Anyway busy day

regards

martin 

On gearbox oil, would this work (and shoot me down, those of you who've actually wrestled with this!):

- cover the necessary leaky bits, and fill it on the bench until it reaches the right level

- drain, noting how much comes out, saving the oil

- install, and then fill using the oil scavenged from the draining

That way, you'd be confident you're putting in the right amount and only need to open the fill hole once it's in place.

N

Count me in. PPG already have my interest and said they would be measuring up a 160 in Jan... 

Re Fuse Box Cover - picture below from Derek on how it fits for when future and current builders are ready. It seems that the box section goes towards the front, the flat section to the rear. In effect it's another 'trim panel' that happens to enclose the fuse box, rather than a fuse box cover per se.

Martin- there should be no need to turn down radius arm sleeves, the right size is in there somewhere and it's difficult to get the wrong one in the worng place.  

Hi peter I've had one of the bushes turned down, took nearly a mill off, actually 25 thou but it now fits a treat.  Count me in for armour fend for the rear wings and I'm leaning towards the B &Q liquid rubber on the inside for stone protection.

 I was also wondering who is up for a 160 meet at some point when we are all ready to go later on in the year

regards

martin

Great idea, Martin. I was thinking exactly the same yesterday!

Ned

Likewise with the 160 meet - great idea. I am also booked into the L7 Club section of the Silverstone Classic on the Fri and Sat - anyone else? 

Another good day, finished the rear suspension and got the shafts in.  Hit a major problem with the engine mounts, after checking out my own photos I realised the main engine mounting bolts that go into the mount needs a spring washer (not mentioned in the manual).  Derek confirmed by email so out came the bolts along with the alignment, I then got the bolt on the skew going back in which proved impossible to tighten and then get out.  The RHS is really difficult to get access to, so after much time and frustration I managed to get the mount out but cleaning up the mount and the bolt was a major task.  Anyhow exhaust now on, handbrake in and IVA paperwork ready to be sent tomorrow

Martin

I've had an idea how we could capture these omissions/amendments from the manual. It worries me that there's no real log of them, and this blog thread has become a goldmine.

The main Blatchat has been yammering on about a Wiki to do this kind of thing, but it hasn't happened.

I've made a Word version of the August 160 manual, and that could easily be transferred into some kind of online editable version (Google Docs, a wiki, etc). It probably breaks Caterham's copyright, but it would be a really handy resource - even for Caterham themselves.

Martin, I know you've spotted many errors too. But we could also add tips, hints, etc.

Anyone interested?