MikeE

Thanks guys. You can pick up new Duratec starters for £60 on eBay so probably just do that as my current on's had the solenoid overhauled once already. Duratec R538 Build and Modification Pictures here

I've got what seems to be the Duratec equivalent of the K-Series click. I've changed my battery for a powervamp having had problems starting and now have the situation where it will start when cold but after a run it won't, it seems to struggle to even turn over. Having read up on the K-Series click it seems to be a bad solder joint on the inside of the solenoid, is it likely to be the same thing with a Duratec starter motor/solenoid? I could just replace the whole starter motor but seems an expensive solution is it is a connection problem.

I paid a surcharge for my Raceline repackable in 2004, can't remeber how much. Yes they do need repacking from time to time! Duratec R538 Build and Modification Pictures here

Yes Danny's played his part in twisting my arm. I tried a Radical, was impressed with the dynamics as you'd expect but was less than impressed with the acceleration (for an £80K car!) - now I know its not about point and squirt before I get attacked again Also don't fancy the idea of a bike engine&gearbox requiring a rebuild every 80 hours or the apparent depreciation. So following that did a bit of research and decided a Juno (with a sealed Honda VTec from a Civic Type R) might be a better option so my mate went and bought one having never driven on track before or in fact seen the Juno! He let me have a go in it and Donnington in september and yes it was very quick and the engine felt stronger than the SR3 but as Danny warned me no hoon factor at all. So I'm in two minds now, if I had the money I'd have both (but then if money wasn't an issue I'd have a Zonda R in flourescent green as a track toy 😬) but I don't so I think the Caterhams more fun, cheaper to run, can be used on the road and easier to sell on....we'll see Duratec R538 Build and Modification Pictures here

You get used to it Ammo, I used to think my 226bhp Raceline 2.0l was more than adequate but after two years I ditched that for your 280bhp 2.3l which was a step up. I now think I'd like more power again but of course each increment costs disproportionately more money so I'll make do for now 😬 Duratec R538 Build and Modification Pictures here

Cheeky git Like you Arnie I'm old enough to remember the original JPE road tests in the 90's which is where I got the idea. And to be fair I have a track record of hideous colour schemes on cars having had a new TVR Tuscans the first in Lambo PINK (6th one built and predictably a dog!) plus the first customer to have a Swordfish spec (Green/Purple flip flop colour) - and very tasteful they were too 😬 I subscribe to the idea that there's no point in having a rediculous car in a subtle colour, go over the top Duratec R538 Build and Modification Pictures here

Try my link below for a flourescent yellow. Duratec R538 Build and Modification Pictures here

Great trailer, just looked on our site (Game.co.uk) and our digital team have editted it down to 60 seconds, should have show the full trailer Duratec R538 Build and Modification Pictures here

Danny didn't realise you'd gone for the big up and over exhaust? Thought you still had the bespoke one? Duratec R538 Build and Modification Pictures here

So got one side of the front suspension back on Saturday and I'm now confused/worried about the new bushes. I've assembled the bushes into the wishbones with a single poly washer at each end and then the usual metal washers to pack out the gap between the bush and the chassis mounting points. These poly washers are now acting as thrust washers to take up the inevitable longitudinal movement when you apply the brakes (or accelerate I guess). The poly washers don't act on the centre sleeve of the bush (like the old rubber bush set up did) but will be mating to the wishbone itself? I'm confused how this will now work as the wishbone bush housing is not supposed to be a bearing surface? I hope the above makes sense, its difficult to put it into words but essentially because the inner sleeve is now free floating you can't use this as the thrust bearing surface, you have to use the wishbone itself? Duratec R538 Build and Modification Pictures here Edited by - MikeE on 11 Oct 2010 12:18:15

Must try harder Arnie! Although to be fair, looking at your old exhaust system it does seem to be a neater construction with the continuous curves, I'm surprised at that the run from collector to silencers isn't straight on the GoodFabs exhaust . Still constemporary F1 exhausts seem to be constructed in small sections (much like Carls). Duratec R538 Build and Modification Pictures here

Ok all the front suspension bits are back from the powder coaters, the Caterham front suspension fixing packs arrived and I have the complete Powerflex bush kit so the reassembly will start this weekend. Are there any tips from those that have done this before? Do the bushes need lubricating? If so which bits, inner and/or outer? What do I do with the plastic washers they've supplied? Do I do away with the metal washers which are normally use to get the right wishbone geometry on the lower chassis mounts? Duratec R538 Build and Modification Pictures here

Richard, is that a personal recommendation of their exhaust polishing skills or the fact they'll make me laugh? I'd like to find somewhere with a track record of producing a finish which last cos last time the primaries went mat grey within days 😔 Duratec R538 Build and Modification Pictures here

Need my Raceline 4 into 1 big bore system polished. Last time I had it done (4 years ago 😳) via Raceline (I think Cheesemans did it) I wasn't particularly impressed with the result and the primaries tarnished before I drove out of the garage! Seen some old threads saying it needs to be a mirror finish or it tarninshes again within a few hundred miles. So any recommendations around Fleet? Duratec R538 Build and Modification Pictures here

All done, now for the powder coat this week and the powerflex bushes arrive this week too. Thanks for everyones advice Duratec R538 Build and Modification Pictures here

Thanks for the offer Dave but im 10 miles from Raceline in Hampshire and you're in Wales? actually I seem to have found the technique now, the first two took 4 hours and lots of swearing, the next two took 40 minutes! So the technique is....saw one cut all the way through the inner sleave, rubber bush and outer sleave and do it towards the wishbone where's there's plenty of meat if you cut a little too far. If you do this and make sure you cut all the way through to the wishbone then you just drive it out with a socket and lump hammer - easy so two wishbones done in a day, lets see if I can do the other two in a couple of hours tomorrow. Duratec R538 Build and Modification Pictures here

YHM Duratec R538 Build and Modification Pictures here

Ian they're an absolute nightmare!! Maybe I have different bushes to you (from a 2004 build) but I've followed your instructions and it just doesn't work. Who do you know who could get them out? Duratec R538 Build and Modification Pictures here

Ok I've spent 3 very frustrating hours trying to get the two bushes out of one upper wishbone. I've managed to cut the inner sleeve and rubber out and then cut through the outer sleeve in two places in the hope it would be easier to get out. I've taken a screwdriver and hammer to them but they still won't shift I don't want to cut them any further as I'm concern I'll put a cut in the wishbone itself - really wish I'd left them in there now 😳 any suggestions?? Duratec R538 Build and Modification Pictures here

Simon you still have the MBs? Duratec R538 Build and Modification Pictures here

Ok taken another look and there is indeed a spring clip under the top collar, so removed it and slid collar and spring off I'm amazed how light the damper is without the spring Now just to ask the question again, after 5,000 miles and 5 years should I get the dampers checked over, does seem like a lot of use Once I get it all back together I'm really hoping to improve the handling, it seems to have got progressively more understeery over the years So I have one way adjustable dampers, 275 & 170 springs, freestyle adjustable front ARB, Caterham rear ARB and run on ACB 10s so why's the balance so crap Duratec R538 Build and Modification Pictures here

Carl I tried that design airbox on my old 2.0l on Jenvey throttle bodies and found the nearside wing would potentially touch it on full lock and compression, figured I'd need a modified back plate to angle it upwards. Just something you might need to consider Edited by - MikeE on 22 Sep 2010 20:24:24

Full set of PowerFlex bushes ordered today from DemonTweaks - £177.34+delivery Going to attempt to cut the bushes out tonight and then get them over to the powder coaters on Saturday, see if I can get it back together by Christmas 😳 Duratec R538 Build and Modification Pictures here

Ian what sort of colour and finish are you aiming for? Duratec R538 Build and Modification Pictures here

So being a little cynical whats the catch http://cgi.ebay.co.uk/Ford-Mondeo-1-8-2-0-16v-Duratec-starter-motor-brand-new-/220618753546?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item335de7060a Duratec R538 Build and Modification Pictures here