Brownmonster Posted May 2 Share Posted May 2 Hi, Just wondering if anyone has any tips on getting these spacers to fit, I've managed to successfully build one side of the car and they were snug, but fit quite easily once they had been in the freezer! The spacers I have left however just do not seem to want to fit on the other side. On the upright, I can get it about 1/2 of the way along the shaft, but dare not "force it" anymore. On the lower wishbone I cannot get anything closer to a fit. I'm going to try leaving the part in the freezer over night, but I'm wondering if anyone else has any tips? Thanks Ste Link to comment Share on other sites More sharing options...
Peter_V Posted May 2 Share Posted May 2 There is one sleeve in the upper wishbone and two in the front damper and although they are all mixed up they only fitted in one part and they just slid in. Same for the top hat and spacer. The spacer just slid on the lower upright with the top hat and nyloc underneath. I know it's not much help to say it was easy on my SV but perhaps something here helps. Picture of spacer on top and top hat under. Link to comment Share on other sites More sharing options...
Ainsley Posted May 3 Share Posted May 3 Are there not two different sizes, one for the SV and one for the normal S3 ? Link to comment Share on other sites More sharing options...
Brownmonster Posted May 3 Author Share Posted May 3 6 hours ago, Peter_V said: There is one sleeve in the upper wishbone and two in the front damper and although they are all mixed up they only fitted in one part and they just slid in. Same for the top hat and spacer. The spacer just slid on the lower upright with the top hat and nyloc underneath. I know it's not much help to say it was easy on my SV but perhaps something here helps. Picture of spacer on top and top hat under. Thanks, I have one side fully assembled and it all fits together nicely exactly as per you pictures. I'm just struggling to repeat on the other side. The spacers on the side that is fitted fit nicely on the other side when I was testing it all out, so I think the two spacers I have that don't fit are slightly out of size. Link to comment Share on other sites More sharing options...
Brownmonster Posted May 3 Author Share Posted May 3 22 minutes ago, Ainsley said: Are there not two different sizes, one for the SV and one for the normal S3 ? Correct, sv uses a top hat spacer underneath and a normal spacer on the upright, together with a half height nyloc. (as per peters pics) Link to comment Share on other sites More sharing options...
Ainsley Posted May 3 Share Posted May 3 OK, so its not a size mix up, just a tolerance issue. You checked the obvious I assume, like any small imperfections on them fouling their fit that could be removed with a file and that they are properly round. Failing that, get Caterham to send you a new set. I messed up on mine and fitted the wrong nut on one side, had me very confused for ages as I had one of each left over. For a week I was convinced it had got lost all by itself. Link to comment Share on other sites More sharing options...
AlastairA Posted May 3 Share Posted May 3 (edited) Put it in the freezer for an hour or so. It's a very tight fit but surprising how easy it is when it's cooled. Link Edited May 3 by AlastairA Link to comment Share on other sites More sharing options...
Brownmonster Posted May 3 Author Share Posted May 3 (edited) 11 minutes ago, AlastairA said: Put it in the freezer for an hour or so. It's a very tight fit but surprising how easy it is when it's cooled. Link Thanks, I tried advice from your blog already! I've left it overnight now, will try again once I'm back from the morning gym session! Not sure how to approach the small spacer not sliding all the way onto the upright base though, perhaps I'll try and heat it (as it is the inverse technique of the top hat spacer!) I'm worried that if I file it that it would compromise the rotation of the joints (great blog BTW) Ill get some photos later as well for completeness in case others also search for this. Edited May 3 by Brownmonster Link to comment Share on other sites More sharing options...
AlastairA Posted May 3 Share Posted May 3 So, just to be clear - the spacer that sits above the wishbone will not slide onto the lower upright bolt? The top hat is successfully fitted into the underside of the wishbone? One side was fine, but the other is too tight? If so, then putting the spacer into the freezer will make the problem worse. I would try letting it warm up again and then apply a small smear of copperslip to see if that helps. Link to comment Share on other sites More sharing options...
Brownmonster Posted May 3 Author Share Posted May 3 (edited) Thanks for the replies, I'm back now, `A picture holds a thousand words' and all that` So, 2 issues for people who look later, this is for the SV build only, and only an issue for the RHS of my build First Issue RHS: The spacer on the upright, of course putting this in the freezer will make it worse so I have not tried that for this, I have tried some silicone lube though (not tried copper slip yet) and still no luck: Second Issue RHS: The top hat spacer does not want to go in at all, I feel like I could sit there for an hour and still be fighting it. I've tried freezing this over night and it still has no chance of fitting, not tried copper slip, have tried lube. Completed Upright LHS: To clarify, I have completed the other side upright fine, I even tested the spacers that I'm having trouble with on the LHS and they would not fit at all on these parts too. this suggests that the two spacers I have left are ever so slightly larger (top hat) and smaller (upright spacer) I'll ping an email to build support to see what they advise. I'm happy to file/dremel/buff or whatever it takes, I just do not want to compromise the integrity of the built upright. Thanks Edited May 3 by Brownmonster Link to comment Share on other sites More sharing options...
Ainsley Posted May 3 Share Posted May 3 So basically its the wrong size, which you have proved on the other side. Id just get them to send more. You don't want to start messing about with a Dremel / big hammer. Link to comment Share on other sites More sharing options...
Peter_V Posted May 3 Share Posted May 3 Just as a test if you put the two together does the spacer fit over the top hat? I think I tried this while messing with them on the bench before I understood where they went and they were a very accurate close fit. Link to comment Share on other sites More sharing options...
Brownmonster Posted May 3 Author Share Posted May 3 (edited) To answer your question, they don't fit. Edited May 3 by Brownmonster Link to comment Share on other sites More sharing options...
AlastairA Posted May 3 Share Posted May 3 Agree with Ainsley - insist on some new parts from CC. Link to comment Share on other sites More sharing options...
Brownmonster Posted May 3 Author Share Posted May 3 (edited) Yeah, I've just spent another 30 minutes having a go and no joy at all, I'll move on with the next steps until I can get an answer from them. I've emailed buildsupport@caterham.com to see what they say. Does anyone know the usual turn around time for a reply? Is it a manned email address during work hours? Edited May 3 by Brownmonster Link to comment Share on other sites More sharing options...
Ainsley Posted May 3 Share Posted May 3 Work hours, but I just send a reminder if I dont get a reply. Normally I got one the following day, only time it took longer was when they were busy moving factory. 1 Link to comment Share on other sites More sharing options...
Matt420R Posted May 3 Share Posted May 3 Emailed them a week ago and haven't had a reply. I haven't chased as I got the answers I needed from the community, but I am a bit dissapointed. Link to comment Share on other sites More sharing options...
Brownmonster Posted May 3 Author Share Posted May 3 I had good response on missing parts, but nothing yet on this issue, was hoping to get a response before the bank holiday weekend but I've got enough to get on with! Link to comment Share on other sites More sharing options...
Brownmonster Posted May 3 Author Share Posted May 3 (edited) Success part 1! Used some 1200 grit sandpaper on the inside, Warmed up the spacer with a heat gun, upright left in the cold. Forced it on not excessive force, but enough to be considered more than expected compared to the LHS As for the top hat spacer, still looks impossible, going to use a heat gun on the wishbone now. Edited May 3 by Brownmonster Link to comment Share on other sites More sharing options...
Ainsley Posted May 3 Share Posted May 3 Well done, but don't force the other too much. 1 Link to comment Share on other sites More sharing options...
Brownmonster Posted May 3 Author Share Posted May 3 (edited) Yeah! Although - the rotation happens on the bearing outside of the top hat spacer so I can probably file the spacer down a bit more and get it to fit fine. Nothing to lose really as they can always send another part if it goes wrong! I'm busy with other stuff this weekend but will keep persisting and trying! I love how with each part that is added, you can really understand the geometry of how it all works, and what is under stress, where it rotates. Really enjoying it all! My day job has always been about programming the maths behind this stuff (especially vehicles, I even wrote some f1 simulator tech for a driver of a red f1 car based in italy, nda prevents saying anything else 🤣) and physics, so to be building this myself is great! Edited May 3 by Brownmonster Link to comment Share on other sites More sharing options...
KnifeySpoony Posted May 4 Share Posted May 4 I had to sand mine to get them to fit as well. Caterham gonna Caterham. 1 Link to comment Share on other sites More sharing options...
Brownmonster Posted May 4 Author Share Posted May 4 5 hours ago, KnifeySpoony said: I had to sand mine to get them to fit as well. Caterham gonna Caterham. What did you sand them with? Hand sand or tool/dremel Link to comment Share on other sites More sharing options...
KnifeySpoony Posted May 4 Share Posted May 4 Just hand sanded with whatever I had lying around. Link to comment Share on other sites More sharing options...
Brownmonster Posted May 6 Author Share Posted May 6 (edited) On 04/05/2024 at 23:26, KnifeySpoony said: Just hand sanded with whatever I had lying around. Mine ended up needing to be attacked with a dremel, still needed a bit of rubber hammer to help it in but wow it was massively too big before, fits lovely now. Leaving this here for anyone else having trouble at this stage in their build! Edited May 6 by Brownmonster Link to comment Share on other sites More sharing options...
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