I completed filling the diff today (I had to ask Caterham for extra oil).

They supplied comma EP80W-90 GL5 Mineral oil. I needed a full 2L before the diff was at the right level (more than the instructions suggest). I found a pipe and funnel seemed to work very slowly but effectively. I just got on with other jobs and occasionally filled up the funnel.

I also sorted out my floppy clutch problem with a wire clamp sent on by Caterham. This isn't mentioned in the August 2014 manual but is in the Jan 3014 one. The clamp fits on the other side of the clutch fork. (See photo)

I was a bit worried about spring washers that should go on the engine mount bolts (thanks Martin) that were not mentioned in the build manual. I really didn't fancy hoisting the engine again and westling to get the bolts back - potential for disaster here. I rang Derek, and Caterham will sort this free of charge at the post build check (and I think that this is fair enough).

I also sorted out the rear lights - no problems here. I just took me a while to realise that the rubber grommet goes on the bodywork hole, not the rear wing hole. I also bust about 4 fuses testing the lights until I realised that the lose number plate wiring was shorting to the bodywork.  .if you are building a 160 don't forget to connect the short fuel tank earth wire to one of the wing bolts (RHS).

Another small success was removing the 12V socket connector under the scuttle (black, purple/red wires) and replacing it with a socket that I bought from ebay. I went on a caving trip, head down, in the footwell and gently levered out the pins with a small screwdriver. The pins fit neatly into my new socket.... sorted... I bought a 12V waterproof socket from ebay that should fit neatly into the 3cm diameter hole in the fuse box cover (hopefully).

Tomorrow I'll finish sorting out the seats. I also need to finishing bleeding the brakes (rather spongy) and solve my engine non starting problem.