CharlesElliott

I might just follow you there Ian. Did you use the existing (6) drilled popper positions, or did you drill one halfway between the harness mountings each side? Charles --- My Caterham Academy 2004 Diary

I've just had another look at mine and the metal strip seems no more than 1mm wider than the metal 'hats' which you use when mounting the harnesses. To drill holes for these in the metal strip would almost definitely end up breaking it into more than one part. So in this case, I may follow the manual and remove it. I'm still not sure why it suggests drilling new holes for the poppers when the pre-drilled ones seem fine. Charles --- My Caterham Academy 2004 Diary

Did people use the existing six holes in the chassis bar that the harnesses bolt into for popper locations? Two of these (one each side) are very close to the harness bolts but it looks as if there is enough clearance. (The reason I ask is the assembly guide says - remove metal strip in boot cover leading edge and discard. Bolt the harnesses through the boot cover. Use the two predrilled holes 1.25" either side of the centre as popper locations. Don't use the other predilled holes (one between the harness mountings and one just outside the outer one) - drill two new holes in the centre of the harness mountings and use those. All seems a bit unecessary to me - but then I may be missing something 😬) Charles --- My Caterham Academy 2004 Diary

I only noted down the web address and unfortunately the site is 'under construction'. There is an email contact given though: www.therollcagepeople.com Charles --- My Caterham Academy 2004 Diary

Rob, Don't know the price as a full cage in mandatory on 2004 cars so I didn't get an option. I know that they do sell Cages direct, but whether they will sell the Caterham one direct is another question. I'll post the details tonight. Oh, and there's a picture of one on the site below.... Charles --- My Caterham Academy 2004 Diary

Marius, The supplier is now caged - I've just got a full cage with my 2004 Academy car. It has all the contact details on it and I could post them tonight if you are interested. One difference is that it now appears you can get to all the harness bolts even with the full cage fitted - and it is easier to fit (allegedly - I've never had to fit an old one). Charles --- My Caterham Academy 2004 Diary

Thanks - I'm pretty sure I got it right but will check again. They did turn, but gradually got stiffer as the torque increased - at 45lbft, they basically won't move at all. Charles --- My Caterham Academy 2004 Diary

Many thanks Pete and Peter T. Peter T: I managed to get one from Pete but thanks very much for the offer. Pete: Thanks very much! Did the trick beautifully and my cage is now well and truly attached. Charles --- My Caterham Academy 2004 Diary

Thanks Alex - just to clarify, did you mean 'it wouldn't turn *with* them'? Charles --- My Caterham Academy 2004 Diary

Subject says it all really. Ideally tomorrow (Sunday). As I was fitting my roll cage I started to cross thread the threaded chassis boss at the front mounting point and now I need to re-cut it. Charles --- My Caterham Academy 2004 Diary

Hopefully a quick question for anyone with four point harnesses (Caterham supplied). I've just fitted mine and expected the black mounting plate to be able to swivel once tightened. But it can't. Is this right? Charles --- My Caterham Academy 2004 Diary

Ed, Most hotels would have just said 'Non' so I suppose it's better than nothing! Was the parking alright? Charles --- My Caterham Academy 2004 Diary

Ed, I'd say it weighed ~10 -15 Kg from carrying it down the stairs yesterday. Do you want something more accurate than that? Charles --- My Caterham Academy 2004 Diary

Tech help don't seem to be answering emails at the moment but James Gibson (who is an absolute star) and Nick Potter at CML have clarified that it is: - two small headed bolts into legs which mount on upper rail behind seats - two nuts/bolts to secure rear legs to brackets; washer on each side of bracket - four 5/8" bolts, two for each leg screwing into boss in chassis with spring washer under the head. So looking from the back of the car, the driver's side sequence is: BOLT > SPRING WASHER > INNER PANEL > CAGE / CHASSIS BOSS / OUTER SKIN < CAGE < SPRING WASHER < BOLT with the inboard cage plate fitting between the inner panel and the chassis boss. Charles --- My Caterham Academy 2004 Diary

Stuart, I should have said 'threaded boss'. Typo . Charles --- My Caterham Academy 2004 Diary

There is a screen, yes - so I assume that means it's a roadsport cage. The cage is made by a company called 'Caged' . Charles --- My Caterham Academy 2004 Diary

Has anyone fitted a full cage recently? Caterham seem to have changed the design and the instructions haven't caught up. Main questions are around the fitting of the two front legs. The instructions I have suggest it is necessary to open up a hole in the outer skin of the car as will as in the interior trim panel but I'm not sure why. The chassis has what looks like a captive bolt already in place on both sides (behind the trim panel). Charles --- My Caterham Academy 2004 Diary

Thanks. Just depressed now that to get them on I had to buy a ball joint splitter, ended up destroying one of the rod end gaiters, put a slight score in the RHS disk with the splitting fork...... *mad* Charles --- My Caterham Academy 2004 Diary

Steve, Are you sure the diagram is different? The one that I'm looking at points to pin 5, but is actually labelled P1. In fact, all the labels look different to the visuals in the drawing. Charles --- My Caterham Academy 2004 Diary

I'm not happy today . Yesterday, I couldn't find the SVA cover for the track rod end. I thought I'd found it when I found a long tapered tube which I cut the end off. As I then picked up with track rod ends, they had a funnel shaped cover on the bolts which I assumed was the 'real' SVA cover and I'd cut the end off some other cover. This morning I realised that these funnel shaped things won't really cover a lot. So the questions are: - What are the funnel shaped things. Are they just protectors that I should bin? - Are the long tapered tubes the real SVA covers? And I need to cut the end off them? 🤔 🤔 🤔 🤔 Charles --- My Caterham Academy 2004 Diary

So then, onto build question #2. After torquing up the upper and lower upright bolts as the manual suggests, I thought that it was a difficult to turn them by hand (as it happens, I can turn the steering column by hand so they aren't that tight). However, I have noticed a contradiction in the assembly guide: Top ball joint (front) to upright - manual text says 45 lbft / 61 Nm (which is what I did). End of chapter summary says 45 lbft / 48 Nm(!). End of manual summary says 35 lbft / 48 Nm. Any one else noticed this and knows which is correct!? The lower upright bolt and wishbone bolts all seem to differ between the main text and the summary at the back - generally they are lower in the summary at the back. Any ideas 🤔 🤔 Charles --- My Caterham Academy 2004 Diary Edited by - CharlesElliott on 7 Sep 2003 11:38:56

Oliver: yes, this needs to be removed (and the washer) 'and discarded' to fit the wing stays and then replaced with a 'low profile' nyloc nut. Luke: thanks again. Charles --- My Caterham Academy 2004 Diary

Thanks Luke. So just to be sure it's the bolt in the centre of the picture here Charles --- My Caterham Academy 2004 Diary Edited by - CharlesElliott on 28 Aug 2003 06:46:08 Edited by - CharlesElliott on 29 Aug 2003 07:09:15

So, what is the stub axle then? I assume it's the threaded thing coming out of the centre of the upright towards the body of the car. I started trying to undo it but it seems prety tight so I wanted to make sure . Charles --- My Caterham Academy 2004 Diary

Thanks Bertie. I agree that going for the Caterham stuff is easiest at the beginning. The info on running in oil is useful though. Did you get any information on brake fluid? Yes, a bit late to organise delivery with the kit, but I only live 1.5 miles from the Surrey showroom who have a display shelf full of Caterham branded fluids for me to choose from . Charles --- My Caterham Academy 2004 Diary