Julian H

Starwars day was Track and Road day.

I visited the super, extremely talented chaps, Steve and Jim in Rainham for a RR session and re-map to maximise the effect of the engine work last autumn / winter. After around 3.5hrs in the workshop I was sent on my way for a testdrive. Melody has been transformed, beautiful to drive, slowly in traffic, or as quick as you like, instant pickup, very driveable. I ended up with 195.6bhp at 7,500rpm, which is more or less maintained to the 8,000 redline. Torque is max 145.3 at 5,500. Two lovely curves, no dips, couldn't be any better. I guess I may have slightly more power without the airbox but the 195[.6] is plenty.

My mate, familiar with pretty tasty cars [ex M3csl and GT3rs owner] said it was f***ing brutal. I liked that! 

Just been cleaned and gone for a rapidBlat 

That's cleaned for the 3rd time this year. No, I am not a polisher 

Saturday 5/3/16 update

Spent the whole day at Partridge Green Motorsport with Andy. Had Melody flatfloored, wheels aligned [included in flat floor], new rear brake pads [Mintex 1144] to balance out my front end lockup concern, and  repacking my front hubs with grease. Those that know Andy will appreciate his experience, attention to detail and care Sevens receive when they visit him for some work. My drive home was completely transformed compared to the outbound journey, and my car was nicer than a couple of others I had driven already.

Also, the first opportunity for a weigh in. 499.5kg including about 15ltrs of fuel. I am very happy with that 

Saturday 27/2/16 update

TB's balanced, ECU tinkered with exactly as Oilys instructions, idle perfect, cold and hot start perfect. instant throttle response, no hesitation, no hiccups. She flys. 

7 dreams and aspiratons...

More power - done 

More carbon

Less weight - getting there 

a return to CR500's

a bike engined Seven

On Saturday 6th of February I set about fitting the throttle bodies to my engine. All went well, a little bit of careful port matching. I had asked Oily to prepare the Jenveys for me so the majority of the work was done. All I had to do was a little bit of smoothing to the cylinder head to match the Jenvey's exit profile. I spent hours loosly assembling them to check alignment and disassembling and working away at the port repeatedly until the proflies matched perfectly. I also removed the old ECU and prepared for the installation of the Emerald. 

I had been very fortunate in receiving the offer and overseeing / assistance of another club member to finish off my engine. So, on the following Saturday, trailer dispatched and we were on our way to his super, spacious and well equipped garage in readiness to start the big work. On arrival we fitted the new engine mount to raise the engine [and quickly realised we would have a problem with the engine now being too high] and stripped down the engine ready for the upgrade process to commence.

On Wednesday 17/2 evening I went round to try and move forward the engine height problem. I removed the new mount and refitted the original and worked out the spacer required to sit the engine at the correct height so Bernards airbox cleared the chassis rail and the bonnet. It turns out that was an 8mm spacer if that helps anyone. We made the spacer up, sprayed it with galvanising spray and fitted it.

On the Friday 19/2 I shot up to see Oily after work and picked up my new cams, injectors, cam belt and tensioner.

So, Saturday the big day arrived. 9.30am prompt I arrived ready to start work. We ended up needing to machine quite a lot of the head away for the arc of the new cam profile, particularly on the low side of the exhaust which needed a few mm. Eventually, after an hour or so's work and around 2 hours clean up operation, we were back to moving forward again. Cams were fitted back in, timing set and crank pulley, belt and alternator reinstalled.

The next day [sunday 21st] first job was to double check the timing which we pronounced spot on after a short while. And then onto the reassembly exercise, Checking, double and triple checking every last bolt was correct etc.., topping up the coolant. Then onto the ECU. Now, that was a whole different ballgame. I have a lot to learn on that! Oily was kind enough to help a couple of times and shortly after we had her back up and running. So, on the trailer and she's home. Next job is to start playing with the idle and balancing the TB's. Hopefully this Saturday morning coming after an hour or so, I will be back on the road 

New engine spec. EU3 1.8K series, Oily's K13 head, Piper BP285H, Jenveys, CF Autoteknix airbox, beige injectors, Emerald, CC 4-2-1 decat exhaust. 

Weight saving, >20.81kg so far

Measures taken

Reverse and fog lamp wedges removal, 74g saving

Banner battery change to LiPo, 5.66kg saving

Boot floor change to Armaboard [front section], 479g saving

Boot floor change to Armaboard [rear section], 1.475kg saving *

Boot carpet removal, 453g saving

Hood hoops removal, 1.134kg

Vinyl boot cover changed to SBFS mohair, circa 250g saving

Rubber mats removal, 1.266kg saving

CF handbrake grip in lieu of ali, 42g saving

CF gearknob in lieu of ali, 154g saving

Jenveys/Autoteknix CF airbox set in lieu of XPower VVC plenum/TB, 2.224kg saving 

Removal of one horn, 293g saving

Secondary headlamp mounting bolts removal, 35g saving

4-2-1 collector in lieu of 4-1 cat, 2.93kg saving and more torque! 

K series unused engine mount removal, 995g saving [thanks Oily  ]

Piper Verniers instead of K series standard, 470g saving

Washerbottle and contents removal, 1.65kg saving [i use an aeroscreen]

WOSP race alternator, saving 1.69kg

Wrapping primaries with Thermo-Tec Cool It, increase 470g 

New 13" Apollo wheels in lieu of 13" 8 spoke anthracites, ? saving

ZZS in lieu of CR500* ? increase 

* I do not recommend these changes.

And still to come

Seat runners removal and direct fix seats to floors, estimated saving 1.6kg

Non-FIA rollbar instead of FIA X bar, saving 2-3kg?

Tunnel carpet removal and replace with CF effect vinyl, saving TBC

Rear bulkhead carpet removal and replace with CF effect vinyl, saving TBC

Boot floor [rear] change to CF from Armaboard, change TBC

Modified rear light blocks, saving TBC

Tidy up wiring on battery reinstallation, shortening cables where possible, saving TBC

Please BM me for any details. Thanks

New kit of parts ready to fit ready to go 

Unexpected bonus is the weight saving compared to my old VVC plenum set up of 2224g 

I never thought I would be the kinda guy that takes bits off his car and has the all over his kitchen table. Cue Caterham ownership and everything changes.  My VVC plenum removed and parts ready to clean for re-assembly onto Jenveys and Bernards airbox. It was a worthwhile exercise because I have spent a few hours thinking about the layout of all the bits and reading Daves, Bernards and Myles [AR7's] website.

Boy are those parts heavy, the two halves of the plenum are over 2kg each!

I have been doing a little painting this afternoon  A little job thats been on the "to do" list for a while.

You can see what it looked like before, above.

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I am sure it will be great fun and a very rewarding experience for you. I only wish i could build one. Maybe one day ill have to settle for re-building mine!

Hi Daniel

I much enjoyed reading your blog last year. And also watching your videos!

Thanks for posting and happy new year!

Julian

Quick snap with new reg. plate and Richcats Ti grille.