rockinroyston

Decided to have a semi day at work & field e-mails whilst I worked out how to do the headlights... followed this method which went OK when I read it properly... http://www.caterhamr500.co.uk/2014/02/build-day-four-headlight-and-indicator.html first attempt I did all the wiring & was very pleased with myself & then I noticed the nutindicator housing & bracket sitting there looking at me... had to take it all apart again.... how I laughed. Couple of things I did that weren't in the details above: I Sprayed rubber lubricant down the floppy tube that comes with the headlight assembly. This made it much easier to push the green wire through with all the other wires. I used shrink wrap to tidy up the ends of the floppy tube, this made it a lot easier to push through the holes in the headlight bracket & it will go through the rubber grommet in the chassis with no issues (I tested it...). Future issues... the green wire is quite short so I'll probably need to extend it when it comes to electrics time... All the other wires are quite long. In the manual its says 'pull the wires into the headlight to get the correct length' LOL, I'll eat my hat if that works but I'll give it a try when I get the lights fitted. as they are soaked in lubricant it might work but I'm not hopeful. I've never used shrink tube before... its great! tested it out on a few random things. Heated it up with a mini propane powered soldering iron (the top bit comes off & it turns into a mini blow torch). Very happy with this bit of kit & my new shrink tubing skills... If in doubt it will be shrink wrapped... I did destroy the soft grommet thing on one of the green wires (as it went in & out of the black tube a few times). Hopefully this is just a seal & i can drop some silicone in or something. Seems too soft to be anything structural in the socket.... hope not anyway. Next project: finish off all the front suspension & headlights. I'm a bit more confident about this as I'm pretty much half way there really. & it means I can put my head in the sand re the 'elephant in the room'... who needs an engine when you have other things to do...

Not really counting this as a proper 'build weekend'... started off badly with a bit of a hangover from the monthly poker night (lost..). So wasn't firing on all cylinders. However the pit crew were super eager to make a start so off we went. 1st job turned the car into a space ship with silvery bubble wrap from B & Q. With two over excited kids & me wandering around in a daze the body work needs all the help it can get! BIt of IVA trim & made a start on the front suspension which went OK. Decided that I would not do the wing stays etc until the engine was in. However come Sunday it dawned on me that the engine & gearbox was probably the next big job... hadn't really mentally geared myself up for that one just yet.... So 'fails' that I noticed after re reading the instructions in the comfort of office, forgot the head lamp brackets... missed off a split washer from one of the shocks. Sent my first e-mail to Derek querying the washer arrangement for an SV. I followed the new book & went for 2 2 2 however the old guided says 0 4 0. I'm sure I read somewhere that the 2 2 2 is the new standard... wont be too much of an issue to take apart & now I've done it once should take half the time... haven't even spotted any horns in my pile of bits & maybe I need to revisit the front lights & wiring... So far so goodish... update Derek has confirmed that 2 2 2 is now the recommended option for an SV & that's good enough for me! he's also confirmed that tightening the wish bone bolts up (at horizontal) without weight on the car is OK & would not damage the bushes. Doing it with the weight on the car is the preference but he acknowledged that getting a torque wrench on them with the engine in could be 'a struggle'.. Found the horns & they aren't bolted together so no breaker bar required...

Its arrived.... the pressures on... Took delivery then ran away... had lunch... checked my emails... had a cup of tea... Ventured back into the garage took a deep breath & started emptying boxes. Succeeded in emptying 3! very satisfied LOL... Now I've had a look at all the bits only saw a few things I had no idea what they were. Thought I was missing the windscreen wipers but then found then hiding under a postage stamp... No proper work done on the car at all but happy that this may be doable! Unfortunately I have a fairly full weekend of ferrying kids around to various activities but hopefully I can make a start on IVA trim & body work protection... no bolting anything on obviously...

After a bit of a wait been given 20th January as my delivery date.... & some pictures from the factory with my name on it!... glad the snows just started my garage will be well toasty .... Last push before delivery: a) Sorted out build insurance, spent a morning ringing around & was surprised at the variety of costs given & also the lack of enthusiasm from some of the 'specialist' providers. In the end I settled on Footman James who were helpful, enthusiastic & the cheapest. £200 fully comp for the build which can be transferred to road mode when required. Bizarrely the cost for 'on the road' is slightly cheaper than the build insurance... so I'll get a rebate, even the broker couldn't explain & put it down to an 'IT glitch'... Most expensive were Reis who were nearer £400-00. b) Re-sorted & cleaned the garage which had taken a turn for the worse over xmas & the project managers car has left mud & grot all over the floor... & the PM's not too happy that her car's going to be booted out onto the road for the foreseeable future (ever)... needs must... c) Last few purchases, masking tape, bubble wrap, pipe lagging, comfy floor tiles, the new yellow floor tiles are like kneeling on ball bearings... oh well it was a good idea at the time & its easy to clean! After all this time waiting I'm panicking that I've already forgotten all the bloggs I've read... tried to look through the manual but without the bits in hand its confusing me more... maybe it will confuse me more when I do have the bits in my hand! a worry... hopefully one step at a time will be easier to digest. Two days to go... not heard from anyone at Caterham regarding actual delivery.. I'll give them a ring tomorrow... All systems go! leaving Dartford at 09-00 so should be with me by midday...

Get yourself one of these too.. https://www.amazon.co.uk/gp/product/B01BEZV0IA/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1 DBPOWER 600A Peak 18000mAh Portable Car Jump Starter Battery Booster Pack Smart Power Bank Charger with Compass, LCD Screen and LED Torch for Laptop Phone Tablet and More (Black/Red) Saves getting the charger out... I have one that starts my Dodge Ram 5.7 litre v8 which quite often drains its battery in the winter if I don't drive it for a week or so, I just keep it in the glove box. You wouldn't believe something so small could turn the engine over... but it does! Unfortunately the truck doesn't fit in the garage & I have to park it down the road... so highly inconvenient to lug the battery around (I've now bought a new battery LOL, which took a while to track one down...).

Well Santa let me down & hasn't even given me a date for January 2017 :-( but on the plus side Amazon have been delivering lots of heavy boxes on a regular basis so the tool kit will be happy! So Merry Xmas & happy new year & hopefully I will be on Blatchat tearing my hair out in January :-)

quite a bit of info on here https://www.lotus7.club/forum/techtalk/headlamp-upgrade

Thanks... nothings easy! I assume when you smash your wing in you just chistle everything off & go back to tie wraps... heres hoping I never have that issue! however doesn't look like I will get my delivery before xmas so wont have this to worry about for a while... more likely I'll be checking the 'sell buy' date on the bonding at the present rate of knots :-(

Thanks for all the pointers! I think I will temporarily shelve my customisation plans until I have a pile of bits in front of me (& its passed its IVA..).

Which thread? I've been looking at the one for headlights but haven't seen one for the rears

Which thread? I've been looking at the one for headlights but haven't seen one for the rears

Thanks all, this makes perfect sense, I'll postpone departing from the spec for the time being! And good point re reflectors.

Big heads purchased & some bonding, they had a split bag so I didn't have to buy 100.... They were very helpful & obviously used to dealing with random Caterham builders... just need something to stick them to now :-(

Has anyone fitted these before & got them IVA approved? or would it be best to use the standard Caterham ones & then change at a later date? Bolt on bits ltd http://www.ebay.co.uk/itm/LED-Rear-Lights-CARBON-Pods-Kit-Car-Caterham-Westfield/231226005167?_trksid=p2047675.c100005.m1851&_trkparms=aid%3D222007%26algo%3DSIC.MBE%26ao%3D2%26asc%3D38661%26meid%3D3af70c321f3443a1b38b77d5c04f39ad%26pid%3D100005%26rk%3D1%26rkt%3D6%26sd%3D390793470890 They seem to be angled etc Not keen on the standard rear lights.. look a bit 'agricultural' (personal opinion!). Are there any other rear end LED options out there? (UK based ideally). Other issue could be with the flasher relay if its LED at the back & normal at the front... questions questions...

Thanks, very useful! I haven't got a radiator in my garage tho :-(

Thanks Phil, I'm still waiting for my Kit to arrive so headlights are away off! but I do like to get organised! I will no doubt re contact you when I'm at this stage. They look great tho so I will be going down that route. I assume you have to squeeze in another wire down the wing stay? (for the indicators). Seems to be an issue that everyone has during their build... I'm hoping that once I have the bits in my hand it will all make a bit more sense (heres hoping!).... suffering from build blogg info overload at the moment, but picked up a lot of info that should help no end! Just sent Caterham an e-mail today asking for an arrival date :-( I have my fingers & toes crossed that it will be before xmas... I put the deposit down beginning of July....

They look great! my electrical knowledge does not extend to diodes tho :-(

just had this response back from them... hopefully someone will give it a go before I get to that stage! £1000 from CC sounds a bit steep to me! https://furoreproducts.co.uk/headlight-3850-lumen-pair They are a straight swap plug wise, I can not say for sure on the housing side having not fitted these to a Caterham myself, the units are supplied with there canbus systems but this is a simple box in the cable that can be disconnected if not needed. They simply need to be plugged in to a H4 connection, all resistors that the lights need are in the lights wiring for the main and dip beam, then it is just a case of wiring up the sidelight and halo, full wiring ijnstructions are sent with the lights

Well its certainly bright! unfortunately still waiting for the pile of boxes to arrive :-( I've also run out of random tools told to buy on Amazon too... waiting is a bit painful!

OK, probably even more of a reason to use big heads rather than making permanent holes in the wings... I'll put this down to something to discuss with Caterham 'nearer the time' as they are putting it through the test for me.... not that its arrived yet LOL. I've scoured the internet for suppliers but only come up with the manufacturer... I'll phone them at some point when I can see & touch what I'm dealing with! its all very well looking at photo's & reading the manual...

Just looking at what I want to do with my wings, much prefer the Bighead method but slightly concerned at the mention if IVA issues? was there ever a response to this? I cant see what the issues would be but.... I assume everyone just gets these direct from Bighead as they appear to be the only supplier I can find & that these come in a 'bulk pack'...

Duramat floor almost complete.... Measure twice cut once... few extra tiles on order DOH! hadn't taken into account the tiles being 'handed' so more waste around the edges than expected... Went for the hi-viz option so I can find all the stuff I drop on the floor... 'Project managers' not quite so sure of my choice... but should match the yellow stripe on the bonnet nicely! Good news on the delivery front too! Caterham have hinted that a December delivery date is now looking 'possible' & my chassis is in 'construction'!

Delivery of a few bits today...Engine hoist, trolley Jack & sundry axle stands. Not sure about the mechanic team's testing methods & I don't think they have read the site safety rules document. May need to reallocate them. Not sure why the photo is on its side... its the right way up when I up load...

Well time is dragging & with only 3 months to go before my delivery date I thought I'd better order some stuff to avoid the Christmas rush.... so engine hoist, axle stands & trolley jack all on their way & be here by next week... ho hum what to do now... thanks to Rob Jones for his link to SGS Engineering...(http://www.sgs-engineering.com/contacts) (http://caterham360build.co.uk/about/) I can see I need a tool box... fortunately for the credit card they were out of stock of the one I wanted... Anyway... hopefully the garage floor arrives next week so that will keep me busy for a day or so..

Good luck, mine arrives in January... I'm hoping for an early December delivery tho... excited & worried in equal measure! so far I've just got the garage to work on... all tidy now, new lights & workshop floor arrives next week...