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700newtons

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Blog Entries posted by 700newtons

  1. 700newtons
    A good friend, Rob, helped with the heater plumbing yesterday. No issues encountered although he did adjust the lengths of pipe to enable the valve to fit snugly between the heater case and the battery.
    (edit 10th Jan. I accidentally put the internal vent plate for the heater the wrong way up. The 'ears' should point downwards to direct warm air into the footwell. Thanks PeterM for commenting)

    He also suggested a pipe connected to the hole in the top of the battery (see photo) apparently these batteries are unsealed an can cause unsightly marks inside the engine bay. This pipe is just cable tied down to the gear box mounting.
    Today I fitted the handbrake mechanism to the chassis. There are two connection points (but one lead). Caterham tell me that the correct connection is the upper one (it is for the handbrake warning light).
    I also went back and removed the headlight bracket and fitted the correct grommets (which were missing from the original pack). I thought that this might be troublesome. However, I used a trolley jack to raise each suspension arm and undo the front bolt for the upper wishbone. It wasn't as tricky as I thought.
     
  2. 700newtons
    I put in the roll bar today. It was only a few bolts but it took a bit of time as the frame is stiff and it required a bit of strength to align the bolts. I was also a bit worried about cross threading the bolts as they went in.

    I opted for a FIA bar (which isn't normally on the options list). I hope it will give greater safety and allow me to perhaps access more events. The FIA bar is different from the normal bar in that it also requires bolts from underneath. To get these in I placed a few layers of cardboard between the frame and the base of the bar. This allowed me to locate the bolts. I then removed the cardboard as I did the bolt up.
    I also gave all touching metal a good covering of copper slip to reduce wear and corrosion (? I assume this is a good thing?)
    The next job was unplanned... I couldn't figure out where one of the heater pipes went. I then remembered a mysterious piece of shiny pipe in a box. Er...this is the 'main water pipe'. I think that this is usually pre fitted to the engine, as there was no mention of it in the instructions.
    I had a few concerned moments when I thought I would have to take the engine out (it is quite big). However in the end I managed to slide it up by the lower steering column (phew).

    The main water pipe is the shiny pipe in the middle. I suggest that 160 builders check it is there before adding the steering column (although you can get it in after)
    (edit 21st dec 2014. NB I originally suggested fitting the pipe to the engine before lowering the engine. However, I don't think that you would get the engine in.)
  3. 700newtons
    After a quite a bit of searching in local shops I bought some 10mm grommets for the headlight brackets. I'm in two minds whether it is worth it though. The cables are already sheathed and I don't think they would wear though.
    Things I have learnt today...
    Holts rubber and nylon lubricant is useful to help get the headlight cables threaded through the brackets (and cursed grommet) silicone sealant is unsuitable for fixing IVA trim around indicators, but locktite superglue works a treat. (I don't think I'll use it on paintwork though) fixing IVA trim around upper wishbone holes seems to be worth doing before fitting the wishbone. It looks difficult to do once the headlamp bracket and wishbone are in. Tomorrow I'll put the dampers in, hopefully.
    (NB advice from me maybe crap - first time I've done this)
  4. 700newtons

    Clutch and Exhaust

    By 700newtons,

    I managed to sort out the clutch cable and make good progress with the exhaust this afternoon.
    By the way, only an idiot would assume that the place to start the clutch would be head down in the footwell. It is all easily accessed by unscrewing the panel just above the steering column.

  5. 700newtons
    After a few days enforced break (a-choo), I'm back on the build.
    I corrected my earth wiring which meant undoing one of the engine mount bolts which inconsiderately slid out of alignment once the bolt was out (and required a whole lot of leverage to get it back). I think that the correct chassis earth connection is just to the left of the battery.
    I connected the front brake pipes, track rod ends and set up the anti roll  bar.
    next job: I'll set about making the engine connections. However, I don't want to get too far with this. I want easy access to the gear box to fill it with oil (which hasn't arrived yet).

  6. 700newtons

    Suzuki Engine in

    By 700newtons,

    We lowered the engine in today.
     
    See a short time lapse film here
     (sorry about the door blocking the view - you weren't expecting BBC production values were you?)I was a bit concerned that the gearbox made contact with the heat proof insulation on the driver's footwell, and it doesn't seem straight as it goes into the transmission tunnel. However, the bolts for the engine mounts slot in (after a bit of leverage) and an email from Caterham confirmed that this is correct.
    We had a good engine hoist - it made it fairly straightforward. I hung it using two climbing slings; one from the engine lifting ring and another with a 'larks foot' around the opposite engine mount bracket and then carefully threaded through the engine to avoid damage.

    The 160 instructions specify one long and one stubby bolt for the LH and RH engine mounts. I think that this must be for older models - both brackets need 2.5 inch bolts.
    After getting the engine in, I made more progress front suspension and got the uprights in (my missing bolts came in the post this morning).  I used a trolley jack to compress the suspension and slot the top wishbone bolts in (with the engine acting as a counterweight)


    One problem I had today is dealing with fiddly bolts on the gearbox mount. I'm having trouble getting spanner to hold the top nut as I torque it from below. I'll try again tomorrow. I'll also finish the front suspension and start doing the engine connections.
     
    (edit 22/12/2014. NB I think that the August 2014 instructions for the gearbox mount bolts maybe wrong. It might be better to use the 20mm bolts rather than the 25mm M8 bolts. The longer bolts look as if they protrude too much and they are also required for the handbrake assembly.  I also found that an M8 washer under the bolt head helped a great deal, it elevated the bolt head so that I could hold it with a spanner while using the torque wrench underneath.) 
     

     
  7. 700newtons
    I have been fiddling with the front suspension today, and this also involves fitting the lighting bracket. The instructions for the lights took a bit more time to understand but I got there in the end.

    Before I can progress much further I need the IVA bag. I thought the the kit should come with fluids too, I have brake fluid, but I will enquire about gear and diff oil. The types Caterham specify seem hard to get hold of.
     
  8. 700newtons

    Corrosion prevention

    By 700newtons,

    I waxed the shell with Autogym for protection - I figured that this might be easier while the car is still in pieces. It also might give a bit of protection from the masking tape I am about to put on around the front suspension area.
    The powder coating on a little of the bottom of the frame was scuffed so I sanded it and painted it with Hammerite.
    I also gave the engine bay a coat of Dimitrol to hopefully reduce the rate of corrosion; especially between the steel and aluminium joints.
     before
     after
    If the Dimitrol looks Ok once dry, I may go and coat more of the underneath.
    (NB I'm making this up as I go along - don't trust me to get it right)
     
     
     
     
  9. 700newtons

    Steering

    By 700newtons,

    The steering rack went in this evening. Before I started I taped card to the outside paintwork for protection against scuffs.

    It seems that I am missing a few components from Caterham (IVA covers and RH lower wishbone). I'll ring up on Monday.
    Tomorrow's job is LH front suspension.
  13. 700newtons
    I previously had a bit of trouble sorting the anti roll bar (I couldn't get the balls in the sockets). I rang Caterham and they suggested I might be using too much grease. I wiped out much of the grease, just leaving a thin layer, and then the balls just popped in with it a few taps of my trusty deadblow hammer.
    While the weather is relatively mild I also coated the inside of the wings with stone chip protective paint. I understand that stone chips from underneath can be visible and stone guard was suggested on 'Bad Bob's build tips'.

    I painted it on (rather than sprayed it). I'm glad I did; the solvent is strong and would make a mess of the paint.
    (edit 22/12/2014. NB if you are planning to bond the front wings, instead of bolt them, it would be worth waiting before painting with stone guard -  - dammit! I'll need to sand some of it off)
  14. 700newtons
    I managed to fit the radiator today. Nothing too difficult. However, I did get stumped by not recognising that to mount the fan on the radiator you need to slot in the little plastic right angled bolt holders. (Thanks Peter M)
    Very annoyingly I also managed to over tighten one of the radiator bobbin nuts and break the bobbin. I'll see if Caterham will send me another.

    12v socket.
    It seems that under the dash there is a two pin socket (black, purple/red). There is also a fuse ready in the fuse box for a power supply. I intend to buy a connector and 12v socket (eBay?) and fit a 12v supply after the car gets through its IVA. (Again thanks Peter for starting me off).
    Petty Strut
    A friend advised me that it might be worth putting a centre punch mark where the petty strut bolts on to the passenger side (behind he aluminium). It can be awkward to locate later. I may use a petty strut at some stage, so I have done this - only a 5 min job.
    Sill Protectors
    It looks like the area under the doors gets quite a bit of abuse. I have ordered some carbon fibre sill prototectors from Carbon mods for about £40 a pair.
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