420R New Style Radiator

[Jonesy365]

Hello..

 

Having a bit of a downer day, everything I seem to be going to do on my 420 kit I seem to be missing bits 😭

 

Just looking at the “new style” radiator (different shown in the manual) and can’t find anything that looks like it would fit it to the car, anyone had experience with the new fixings please?

Where they are and what they look like?

Thanks  

[Jonathan Kay]

More later, please see posts on avoiding stress from mountings. 

Jonathan

[cobar]

Here are a couple of photos taken during my build that show the mounts in place.  As seen in the second photo, the factory didn't sufficiently bend the bracket to create a parallel mounting surface for the radiator, so that had to be done to fit.  It's a thick piece that took some persuasion to get right.

 

[Jonesy365]

1 hour ago, cobar said:

Here are a couple of photos taken during my build that show the mounts in place.  As seen in the second photo, the factory didn't sufficiently bend the bracket to create a parallel mounting surface for the radiator, so that had to be done to fit.  It's a thick piece that took some persuasion to get right.

 

That’s amazing thank you!

By any chance can you remember where you found the nuts and bolts, I have the rubber mountings and found the metal plates. 
 

Always worried I’ll use the wrong bolts that are intended for something else. 
 

Thanks. 

[Graham Hutton]

As Cobar says, very important to bend those aluminium mounting plates so the front face is parallel, then slot the holes if necessary and use some extra spacing washers to make sure there is no residual bending stress in the radiator. Learned from experience I am afraid!

[cobar]

1 hour ago, Jonesy365 said:

By any chance can you remember where you found the nuts and bolts, I have the rubber mountings and found the metal plates. 

I don't recall those being hard to find. Have you checked the fastener pack for the cooling system?

[Jonathan Kay]

As above: It doesn't matter what you have to do to the brackets or the chassis end as long as there isn't any stress on the radiator.

And the same goes for the hoses.

Jonathan

[CO2MAX]

I found most of the fixings in Pack D Cooling. I did however buy some half-height Nyloc nuts for attaching the fan as Caterham didn’t supply these and others have noted the full height nuts are an IVA fail. They also didn’t supply 2x M8 10mm bolts which you’ll need for attaching the bobbins to the lower mounting slots on the radiator. (I have 98 extra ones😂 if you need some just PM me).

I too had to bend the aluminium brackets after reading various threads on radiator stress on this forum - hopefully I’ve got this right🤞. The photo below gives a close up of one bobbin just prior to tightening up - you might find it useful.

Cheers, Craig.

[Nigel B]

Was there not also an issue with the radiator top hose outlet being in a slightly different position to the previous design of radiator?

But Caterham were still supplying the original design of top hose that now needed to be bent a little to fit the new radiator, adding to potential twisting stresses on the rad.

 It probably worth checking that it fits correctly. Or perhaps Caterham have now amended the design of the top hose?

[ScottR400D]

Hi Nigel. The top hose they use was designed for the original radiator set up as you and I have, I think. 
For that set up it fitted well,  now it’s a poor fit all round. 
I’ve seen several efforts to get it to fit with cable ties etc.  

[Nigel B]

Hi Peter!

You’d have hoped they’d have sorted out an appropriate replacement by now. I suppose the key thing is to ensure there’s no tension transferred to the outlet pipe (or is it the inlet pipe?).

 I hope you’re doing well. 👍

[Jonathan Kay]

9 minutes ago, Nigel B said:

I suppose the key thing is to ensure there’s no tension transferred to the outlet pipe (or is it the inlet pipe?).

No tension, compression, angulation, rotation... just like the mounts.

But i don't know all of the options for avoiding these.  

Jonathan

[Peter_V]

I notice that the pictures here show the bracket on the inside of the chassis mounting and in the 2015c written manual they are outboard of the mountings. I'm not sure which if any is correct but it's an additional option to get the least stress fitting. I haven't fitted mine yet as one bracket was missing. BTW the IKEA manual doesn't even show the SV brackets.

[StevehS3]

Separately, that sharp yellow spike pushed into the radiator fins can be a future problem if it vibrates and punctures the radiator. 

[SM25T]

1 hour ago, StevehS3 said:

Separately, that sharp yellow spike pushed into the radiator fins can be a future problem if it vibrates and punctures the radiator. 

What is it for ?

[ScottR400D]

5 hours ago, Nigel B said:

Hi Peter!

You’d have hoped they’d have sorted out an appropriate replacement by now. I suppose the key thing is to ensure there’s no tension transferred to the outlet pipe (or is it the inlet pipe?).

 I hope you’re doing well. 👍

Not too bad Nigel. Had a few health things but hopefully getting there. 
Haven't used 7 this year yet. Came to it in spring to find a rear leaky damper so I’ve got a set of Nitrons being fitted just now, flat floor,  MOT etc 
Hopefully back in a couple of days or so but not sure when I’ll be able to drive it but my son will be having it away to Silverstone if I can’t!  To be fair he paid for the Nitrons so I can’t complain!

I hope you’re well? 

[StevehS3]

2 hours ago, SM25T said:

What is it for ?

I don’t know. I assume it indicates a manufacturing batch number or something like that. It is a nasty spike to push into the radiator though. 

[Jonesy365]

Evening all

Flowing on from the above post I received the correct brackets from Caterham so radiator fitted. 
 

I know there has been a lot of posts about radiator failures, I test fitted the nose cone (car is 420 but I ordered it with the 620 nose cone) this evening before filling fluids and the nose cone rests / pushes on the top of the radiator. 
Does anyone else have a 420R SV with new style radiator/brackets and 620 nose cone have the same?

Is it something to worry about, I have emailed Caterham so will see what they say in the morning  

thanks again 😃

[Jonathan Kay]

15 minutes ago, Jonesy365 said:

... I test fitted the nose cone (car is 420 but I ordered it with the 620 nose cone) this evening before filling fluids and the nose cone rests / pushes on the top of the radiator. 

Please could you add some photos of the radiator and how it's mounted.

Thanks

Jonathan

[cobar]

  

6 minutes ago, Jonesy365 said:

Does anyone else have a 420R SV with new style radiator/brackets and 620 nose cone have the same?

Yes, me.  I recently discovered wear marks on the top of the radiator caused by contact from the vent screen where it bonds to the underside of the nosecone. I temporarily inserted pieces of excess rubber trim for the rear wings to stop the rubbing; temporarily because I intended a more permanent fix, and because the trim pieces fell out during the subsequent test drive 🙂 My plan is to slightly oval the radiator mount holes to drop the radiator by a few mm, but I'd love to hear what Caterham suggests.  

[Jonesy365]

5 minutes ago, Jonathan Kay said:

Please could you add some photos of the radiator and how it's mounted.

Thanks

Jonathan

Photos below. 

[Jonesy365]

3 minutes ago, cobar said:

  

Yes, me.  I recently discovered wear marks on the top of the radiator caused by contact from the vent screen where it bonds to the underside of the nosecone. I temporarily inserted pieces of excess rubber trim for the rear wings to stop the rubbing; temporarily because I intended a more permanent fix, and because the trim pieces fell out during the subsequent test drive 🙂 My plan is to slightly oval the radiator mount holes to drop the radiator by a few mm, but I'd love to hear what Caterham suggests.  

I was thinking of trying lowering the radiator as you say but there is no play in the bottom oil hose on the left side so was thinking this may not work. 
I’ll let you know what Caterham say. 

[Jonathan Kay]

Thanks for the photos. I was also wondering about fettling the mounts to drop it a bit.

Jonathan

[Brownmonster]

1 hour ago, Jonesy365 said:

I was thinking of trying lowering the radiator as you say but there is no play in the bottom oil hose on the left side so was thinking this may not work. 
I’ll let you know what Caterham say. 

I'm at the same point and will try my nose cone, I've noticed that you have used the larger right angled lower rad hose extension, mine fitted fine without that 420r sv as well. A little confusing why our kits would differ given they were likely built at the same time! 

Have a gander at www.caterham420rbuild.co.uk and you'll see what I mean with the lower hose. 

[Jonesy365]

I had the incorrect radiator brackets delivered, when emailing Caterham about it they said to install the way I have in the email, I have screen shot below for reference. 
 

Your blog looks great, I did think about doing one but I haven’t got the discipline to document properly and get carried away moving onto next stages. 
 

When did you receive your kit, I’m trying to book my IVA for early/ mid July.