We lowered the engine in today. See a short time lapse film here
(sorry about the door blocking the view - you weren't expecting BBC production values were you?)I was a bit concerned that the gearbox made contact with the heat proof insulation on the driver's footwell, and it doesn't seem straight as it goes into the transmission tunnel. However, the bolts for the engine mounts slot in (after a bit of leverage) and an email from Caterham confirmed that this is correct. We had a good engine
I worked on the engine bay today. Horns and washer bottle in; no problems. I also stuck cardboard all around in an attempt to reduce the chance of damage as the engine is lowered I got rather confused when putting in the rubber engine mounts. There are four bolts; 3 are 45mm long, one is 50mm - I couldn't see why. However, I think the the engine earth connection is supposed to go here. (edit 11th December - no, Earth lead cannot go here, it would rest on the exhaust and here is an obvious earth
I decided to make a start on the gearbox. (I can't finish the front suspension until I get a couple of 1/2" nuts). The components seem to fit well, and I had few problems. The only thing that confused me was the 4 fixings that attach the gearbox to the engine. The top two fixings are 10M X 50mm bolts, the bottom two fixings are a shaft with 10mm threads at either end and a bolt to lock it off. Derek at Caterham was helpful. I also took the time to give the area between the body and the fuel tan
I put in the front dampers today and caught up on the RHS. I also torqued up the bolts specified in the instructions. However, the top damper bolt was inaccessible for the torque wrench (and my ingenuity) so I did my best guess at 20Nm after practising with the torque wrench. After setting bolts to the correct tension I gave them a dab of tippex (to reduce OCD paranoia at the end). I wanted to put upright attachments in today. However, I think I'm missing a 1/2" nyloc nut that should be on the
After a quite a bit of searching in local shops I bought some 10mm grommets for the headlight brackets. I'm in two minds whether it is worth it though. The cables are already sheathed and I don't think they would wear though. Things I have learnt today... Holts rubber and nylon lubricant is useful to help get the headlight cables threaded through the brackets (and cursed grommet) silicone sealant is unsuitable for fixing IVA trim around indicators, but locktite superglue works a treat. (I don'
I have been fiddling with the front suspension today, and this also involves fitting the lighting bracket. The instructions for the lights took a bit more time to understand but I got there in the end. Before I can progress much further I need the IVA bag. I thought the the kit should come with fluids too, I have brake fluid, but I will enquire about gear and diff oil. The types Caterham specify seem hard to get hold of.
The steering rack went in this evening. Before I started I taped card to the outside paintwork for protection against scuffs. It seems that I am missing a few components from Caterham (IVA covers and RH lower wishbone). I'll ring up on Monday. Tomorrow's job is LH front suspension.
I waxed the shell with Autogym for protection - I figured that this might be easier while the car is still in pieces. It also might give a bit of protection from the masking tape I am about to put on around the front suspension area. The powder coating on a little of the bottom of the frame was scuffed so I sanded it and painted it with Hammerite. I also gave the engine bay a coat of Dimitrol to hopefully reduce the rate of corrosion; especially between the steel and aluminium joints. before a
I ordered my 160 in April 2014. Here is my blog. I hope it maybe useful and interesting to others. Caterham 160 Expected delivery November 2014. Full Screen and weather equipment, carpets, lowered floors, push button start, leather seats, Momo steering wheel, heater, Race 4pt harness, Track day roll bar. Ballistic orange The lowered floor provides the driver with a clearer view and the 4pt harness and track day roll bar are for improved safety. I understand that access the Lotus 7 club track
