Exhaust Hole Template

[Kermit the K]

Can anyone send or fax me the Caterham template used to cut the larger hole in the side of the car for the 4-1 race exhaust system?

 

Phoned CC but they won't send me one ☹️

 

Won't be back online for a few days, but I will get back to you if you can help, or give me a ring - 07791 790 487.

 

Thanks,

 

Chris.

 

Everything Louder Than Everything Else - Lemmy, Motorhead.

[Dave McCulloch]

Kermit

 

I have a template for the 4-2-1 manifold as fitted to the SLR - don't know if this is the same as the hole required for the 4-1 performance system. If someone can confirm, I can send you a copy. - Actually I have two templates - a larger hole which is as Caterham sent to me, and a smaller hole version which shows the actual hole I ended up making (quite a bit smaller btw!)

 

Dave

[Myles]

When we did my 4-1 a month or so ago, we didn't use a template -and I think we ended up with a bloody good result (here) - although, if you want to be picky, the top edge could have possibly tapered down slightly.

 

What we did was to start with one primary (the one that exits top-left, IIRC) and work away at that until the clearance seemed OK. From this point, we drew the horizontal and vertical lines (i.e. left and top edges) and worked away at those corners - and repeated the exercise for the bottom-right.

 

The important thing to note is that the clearance on individual primaries might be fine when trial-fitted - but when you get to the point of trying to get all four in at once, you might need to enlarge the hole slightly for installation reasons only.

 

Incidentally, we did most of the work with decent convex files - and only a little with a nibbler...

 

...don't forget to cover a large area of the panelling with a double layer of masking tape first though...

 

Final point - my chassis is a race de-dion and doesn't have removable braces - we ended up having to undo the two main engine mounts and raising the engine an inch or two in order to get the old, crummy, internal 4-1 collector/manifold out.

 

There are a few more details of our installation here

 

Regds,

Myles

 

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[Richard Price]

Kermit,

I've just fitted a 4-1 manifold and system, without a template.

I loosely fitted each primary in turn, checking where it made contact with the side skin, marking this area, removing the primary, opening out the cutout, then refitting primary more tightly, mark and cut again until the primary flange will fit correctly onto the head.

I think I was all done cutting the hole in about an hour.

The most difficult part was removing the original short 4 branch manifold! You will need to lift the front of the car, jack under the engine, remove the LHS engine mount, swing the engine over to the LHS, then the manifold can be dropped and twisted out underneath.

[Richard Price]

Guess Myles was typing at the same time as me!!!! (but I'm supposed to be working!)

[Kermit the K]

Thanks for the info chaps, Dave, YHM.

 

I'll be back online in a few days.

 

Everything Louder Than Everything Else - Lemmy, Motorhead.

[Dave McCulloch]

Kermit

 

I've photocopied both the Caterham supplied template and the one I made, together with the instructions sheet - will try to get them in the post tomorrow.

 

Please do check that the 4-2-1 template is suitable - and enlarge the existing hole gradually checking the fit of each primary as you go - I don't know the tolerance they work to in the dimensions of the primaries and the bends made.

 

Dave

[Kermit the K]

thanks dave, much appreciated.

 

 

 

Everything Louder Than Everything Else - Lemmy, Motorhead.