Peter_V

Thanks. Following advice here I fitted the bulkhead carpet, made holes for the harness bolts in the vinyl strip and re fitted the boot cover over the top. I then fitted the shoulder harness stacks. That enabled me to fit the track day roll bar. I haven't glued the carpet down yet as I need to access the upper damper bolts but really happy how it's going.

Just as a test if you put the two together does the spacer fit over the top hat? I think I tried this while messing with them on the bench before I understood where they went and they were a very accurate close fit.

There is one sleeve in the upper wishbone and two in the front damper and although they are all mixed up they only fitted in one part and they just slid in. Same for the top hat and spacer. The spacer just slid on the lower upright with the top hat and nyloc underneath. I know it's not much help to say it was easy on my SV but perhaps something here helps. Picture of spacer on top and top hat under.

Excellent help everyone, thank you. I just didn't want to get it wrong and have to remove the roll bar.

2024 build 420R 5-speed the mazda box said M53F-03-000

I'm installing the shoulder straps on my 420R SV and could do with some advice please. The belts each come with a bolt, plain washer, crinkle (wavey) washer, top hat and a cardboard washer! The build manual is pretty random but I think the stack order is Bolt, washer, harness, crinkle washer and then top hat. No idea about the cardboard washer. CC have pre-drilled the boot cover, which includes an aluminium strip sandwiched inside, with holes large enough to take the bolts but not the top hat. This means the top hat will be sitting on top of the boot cover fabric. It seems strange that a safety device is torqued down onto fabric. Is this correct or do I need to make the holes larger so the top hat sits on the metal cross member underneath? I can't find a clear picture in any of the build blogs. Advice appreciated. Many thanks Peter.

They are in the miscellaneous pack 49. The give away is that there are 3 M8x45 bolts and 1 M8x50 for the earth that isn't used anymore! The M8 nyloc and washers are in the same pack. I left the single bolt long as a nod to the old days..

On my 2024 build the gearbox is tight everywhere but without the spacer it would be resting on the lower chassis rail on the LHS. So not an alignment concern but worth having for clearance if you have issues at that same point. Picture of gap to chassis.

Same issue on my 420sv. Agree with Simon and just removed a small amount of metal from mount with a half round file and then repainted.

For my ongoing 420 sv build I had the same thoughts about the -ve wires from the battery. However, I read on the tiggercaterham.co.uk blog that during the PBC Caterham moved the -ve wire away from the hot exhaust on the RHS to the starter motor retaining bolt on the engine LHS. I've done this with the long wire and it looks quite tidy. This has left me with a short -ve lead from the battery to the chassis earth point next to the battery as page 95 of the guide. I therfore don't have a chassis earth connection under the LHS engine mount even though they still supply one longer bolt for this in the kit. I presume this requirement has been superseded by the earth point next to the battery. Happy to be corrected here.

Same issue on my 420R build. You only need to open the tab up a few mm to make a big difference in the hole alignment for the bolt. I used a screwdriver and both sides covered in masking tape and then moved to flat faced pliers but it didn't take much to enable a nice fit and feel the bracket won't tip down with vibration. I'd also say the tab isn't that strong so it is possible to hand hold bracket and tools while adjusting. Hope that helps.

I'm two weeks into my 420R build and have just finished the headlights. I do remember they were difficult to close and needed the top edge to engage first and also careful alignment where the screw holes were going to end up (as difficult to rotate after) then firm pressure at the bottom and they clipped shut. Hope that helps.