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Thread: New Build

  1. #61
    Join Date
    Jan 2020
    Posts
    43

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    Quote Originally Posted by BruceBe View Post
    Ok Greg - it's been a long rainy weekend. Perfect weather for some build progress...let's see it :-)

    Cheers,
    -Bruce
    It was a productive weekend Bruce. Taxes are done and that black Subaru you saw in my driveway made it to my son's place under its own power. I also managed to grab a few hours to work on the Seven and now have the front suspension assembled if not fully torqued. Despite taping and taking care, I found it difficult to not have some paint damage behind the nut on the front upper wishbone. Granted it is behind the nut and hard to see, but it is a little mystifying that there is about one mil of space between a nut, aluminum skin and the bracket for the wishbone. No idea why the factory doesn't make the hole in the skin a little bigger so the skin can flex behind the bracket rather than sit on top and get pinched.

    I am learning though. Whereas in some vehicles I would assume tolerances were such that at the right angle and with some gentle force things will go together, Caterham tends to do things a little differently. I've now run into two situations where a little filing made more sense than a lot of force. Some of the issue with tolerances seems to be simply paint.

    Speaking of paint, I read somewhere that the chassis is powder coated but to my eye it is paint. The inside of the upper shock mount flaked off like paint with bushing contact, and I've noticed some very minor chipping elsewhere. I realize that once on the road the chassis is going to get chipped, but being a bit detail orientated (aka anal) I've been touching up anyplace where bare steel is exposed. Not sure what you pros use, but the original formulation of Rust-Oleum in satin is a good match.

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    Greg

  2. #62
    Join Date
    Feb 2009
    Location
    NYC
    Posts
    4,764

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    Its fair to say that Caterham kits are not quite like Ikea product assembly.

    I think you need some build inspiration right now. When you are finished, Bruce will give you some coaching and you will have your 420R performing like this 420 is.






    Keep the good work coming!

    Mike
    2010 Caterham CSR with Cosworth 2.3 Duratec
    2018 Caterham 420R with 2L Duratec 210hp at Donington UK
    1975 BMW CSL Group 4 (restoration - engine and dry sump install time)
    1977 Holden Torana "A9X" (awaiting restoration)
    1985 Holden Commodore SS Group A
    1985 Holden Commodore Group A
    1982 Ferrari 400i
    1965 Ford Mustang Fastback "Holman Moody"
    1992 Ford Escort RS Cosworth WRC (fettling after long period of storage)
    1990 Range Rover 2 door Classic
    and another project car coming....

  3. #63
    Join Date
    Jan 2020
    Posts
    43

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    Quote Originally Posted by Croc View Post
    Its fair to say that Caterham kits are not quite like Ikea product assembly.

    I think you need some build inspiration right now. When you are finished, Bruce will give you some coaching and you will have your 420R performing like this 420 is.






    Keep the good work coming!

    Thanks Mike. I enjoyed that.
    Greg

  4. #64
    Join Date
    Jan 2020
    Posts
    43

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    How about a game of name that part? I found this in my box of shortages:

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    This foot long piece of rubber trim doesn't seem to have a match in any other box, and I've not found a reference to it in either build manual. Someone who blogged about building a 420R has a description of trim around the body panel openings for the front suspension, but this wouldn't look to be for that purpose, there wouldn't be enough of it anyway, and I'm thinking that trim is strictly for the IVA in the UK?
    Greg

  5. #65
    Join Date
    Feb 2009
    Location
    NYC
    Posts
    4,764

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    It looks like the scuttle edge trim - no where near enough of it mind you. Technically it is an SVA bit but it is good for finishing off the dash area and prevent paint chips on the edge facing the driver. I installed it on my US Caterhams for that reason alone although I forgot to on the UK 420R.

    https://caterhamparts.co.uk/scuttle-...tle&results=19

    Photo of the edge trim installed




    Edge trim on my 2010 silver CSR




    My 420R dash without the edge trim installed

    Last edited by Croc; 02-22-2020 at 03:18 AM.
    Mike
    2010 Caterham CSR with Cosworth 2.3 Duratec
    2018 Caterham 420R with 2L Duratec 210hp at Donington UK
    1975 BMW CSL Group 4 (restoration - engine and dry sump install time)
    1977 Holden Torana "A9X" (awaiting restoration)
    1985 Holden Commodore SS Group A
    1985 Holden Commodore Group A
    1982 Ferrari 400i
    1965 Ford Mustang Fastback "Holman Moody"
    1992 Ford Escort RS Cosworth WRC (fettling after long period of storage)
    1990 Range Rover 2 door Classic
    and another project car coming....

  6. #66
    Join Date
    Jan 2018
    Location
    Birmingham, Alabama
    Posts
    17

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    Quote Originally Posted by Pokey View Post
    How about a game of name that part? I found this in my box of shortages:

    Name:  IMG_3259.jpg
Views: 207
Size:  50.5 KB

    This foot long piece of rubber trim doesn't seem to have a match in any other box, and I've not found a reference to it in either build manual. Someone who blogged about building a 420R has a description of trim around the body panel openings for the front suspension, but this wouldn't look to be for that purpose, there wouldn't be enough of it anyway, and I'm thinking that trim is strictly for the IVA in the UK?
    It maybe the trim for the air inlet box, item 4 on page 31 of the assembly guide?

  7. #67
    Join Date
    Jan 2018
    Location
    Wellsboro, PA
    Posts
    75

    Default

    It is the trim for the air box. I scratched my head for a couple days on that also. Looks nothing like the picture in the guide... LOL. Also don't torque down the rack until later. You WILL need to loosen it to line up the steering column with the U-joint. I tried my best to "eyeball it" but needed to twist the rack later anyways... I waited to torque a lot of the suspension bushings until it was on the ground with the engine in. With the suspension hanging,(upper and lower a-frames, radius arms etc.) I didn't want to tighten everything to spec at their lowest point of travel, then have them damaged after it was on the ground.
    The steering column bushings were a real pain! I wish i had a nickel for every time I pushed the one just behind the dash thru. Use plenty of lube!
    Also. I installed probably 95% of the heater and radiator house before putting the engine in. I have no idea how they expect you to get some of them in after the engine is in the car!. Like the "U" hose that's practically under the battery. Sheesh.


    Keep us posted. Good luck! I've got a lot more advice of you need it.
    Kenny

  8. #68
    Join Date
    Feb 2009
    Location
    NYC
    Posts
    4,764

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    Quote Originally Posted by Lucky-7 View Post
    It is the trim for the air box.
    Kenny
    Good spot! I was puzzled why it was so short.
    Mike
    2010 Caterham CSR with Cosworth 2.3 Duratec
    2018 Caterham 420R with 2L Duratec 210hp at Donington UK
    1975 BMW CSL Group 4 (restoration - engine and dry sump install time)
    1977 Holden Torana "A9X" (awaiting restoration)
    1985 Holden Commodore SS Group A
    1985 Holden Commodore Group A
    1982 Ferrari 400i
    1965 Ford Mustang Fastback "Holman Moody"
    1992 Ford Escort RS Cosworth WRC (fettling after long period of storage)
    1990 Range Rover 2 door Classic
    and another project car coming....

  9. #69
    Join Date
    Feb 2009
    Location
    NYC
    Posts
    4,764

    Default

    Quote Originally Posted by Lucky-7 View Post
    I've got a lot more advice of you need it.
    Kenny
    Like 'Never fry bacon naked'?
    Mike
    2010 Caterham CSR with Cosworth 2.3 Duratec
    2018 Caterham 420R with 2L Duratec 210hp at Donington UK
    1975 BMW CSL Group 4 (restoration - engine and dry sump install time)
    1977 Holden Torana "A9X" (awaiting restoration)
    1985 Holden Commodore SS Group A
    1985 Holden Commodore Group A
    1982 Ferrari 400i
    1965 Ford Mustang Fastback "Holman Moody"
    1992 Ford Escort RS Cosworth WRC (fettling after long period of storage)
    1990 Range Rover 2 door Classic
    and another project car coming....

  10. #70
    Join Date
    Jan 2020
    Posts
    43

    Default

    Quote Originally Posted by Lucky-7 View Post
    It is the trim for the air box. I scratched my head for a couple days on that also. Looks nothing like the picture in the guide... LOL. Also don't torque down the rack until later. You WILL need to loosen it to line up the steering column with the U-joint. I tried my best to "eyeball it" but needed to twist the rack later anyways... I waited to torque a lot of the suspension bushings until it was on the ground with the engine in. With the suspension hanging,(upper and lower a-frames, radius arms etc.) I didn't want to tighten everything to spec at their lowest point of travel, then have them damaged after it was on the ground.
    The steering column bushings were a real pain! I wish i had a nickel for every time I pushed the one just behind the dash thru. Use plenty of lube!
    Also. I installed probably 95% of the heater and radiator house before putting the engine in. I have no idea how they expect you to get some of them in after the engine is in the car!. Like the "U" hose that's practically under the battery. Sheesh.


    Keep us posted. Good luck! I've got a lot more advice of you need it.
    Kenny
    We have a winner! You just saved me a lot of head scratching trying to figure out what this random bit of rubber in the shortages box was for.

    I've already torqued the rack not knowing better, but did lay the steering column in to get alignment. Fingers crossed. For the suspension I removed the shock from the top mount and jacked the bottom wishbone to horizontal before torquing. I've made the assumption that horizontal is the neutral position... if it isn't I would appreciate no one telling me.

    I'm going to do as you suggest and route hoses first, thanks for the tips Kenny, much appreciated.
    Last edited by Pokey; 02-23-2020 at 12:25 PM.
    Greg

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