700newtons

After seeing some of the 160 photos I decided I wasn't quite happy with my headlamp wiring. So I redid them. I cut a small hole in the black cable sheath, and inserted the indicator wires. I'm told by the fellows at Caterham, that an alternative is to use tape to cover bare wires. You can see my wheels in the background. They arrived yesterday along with my back axle casing. However, I still need to get hold of the gear and diff oils. The specified oils are only sold in large quantities, so I need them from Caterham.

Thanks for that - I haven't had time to look yet... I had some good news today, my rear axle and wheels will be coming on Thursday. All being well, hopefully the oils too.

Thanks Peter. Interesting. I hope my axle casing comes soon. Was the gasket sealer supplied or did you buy your own? If so what did you get? Another thing, do you find the you have quite a few bolts and bits and pieces left over? I have quite a few hose holders etc, and I'm not certain of their purpose. There is a large clip mounted to the engine near the exhaust catalyst too. I have yet to discover what it is for... Simon

Yes, my thoughts too... Let's hope we are right. Edit - I checked the build manual; and I have followed the instructions.

.... In memory of great, but unknown, nuclear physicists...

Thanks, I was thinking of trying to get the IVA done myself in Taunton. It might be cheaper for me to try, and retry, for an IVA than get the car trailered up to Dartford for a post build check. I'm not fully decided yet though. I'll investigate what you suggest.

It is interesting to look at the headlamp wiring too... I notice that in both orange and blue cars they get the indicator cables in the sheath (by making a hole) and the bracket has a grommet where the wires go in. I don't fancy taking them off again...

I notice that the pictures of the car tax badge show £145. I thought it was going to be £30. Anyone know? orange is definately a good colour...

click here: google docs for a range of 160 pictures (kindly sent to me by Martin B2). This might be a useful resource for new 160 builders.

Hello Peter, whoa... You have a back axle casing?! I'm still waiting for mine. I better get onto Caterham. Do you have the oils and wheels yet? In answer to your questions: The wiring harness tucks into a tidy space just under the battery ECU. There is a nice little route for this. (A friend spotted this, not me). You can secure it with cable ties. The plugs go neatly into the bottom of the ECU. (Have I understood the question?) Yes I plugged the earth lead into the threaded hole just to the left of the battery. I'm told a spring washer helps ensure a good connection. The other lead goes to the starter motor bolt (it says this in the instructions for the starter motor, I think). I think my fuel hose looks ok but I'm holding off before plugging it in (as you can't undo it easily). I was going to get the gearbox oil in and check my other plumbing first but I could be just OCD. by the way, I got MartinB's photos today. I'll upload them and post a link shortly. simon

Thanks for this - it will be useful.

Thanks Martin. (A private mail sent). if you don't mind I'll upload a few pictures so that more people could see it (credited to you of course!). Simon

Thanks both - especially your photos Mike. What would also quite like to see is the vacuum hoses just under the nose cone. If you have a photo of that I'd be happy. Not long before you pick up spanners then.... Simon

If there is a 160 owner reading this I would be grateful to see a photo of the engine bay with good resolution. Before starting the engine, further down the line, I would like to double check my connections. The build manual photo is OK, but I can't quite see the fine detail.

I added the intercooler today. No big issues but it is an easier job if you get some of the hoses in place first (there is not a lot of space). That is all the progress I can make for the time being. I'll start work again once I get the back axle casing from Caterham. (I understand they are on their way from Japan).

Peter: good call with the heater. My internal vent plate was upside down; it seems obvious now. My missus (and I) will now have warm feet.

Peter: thanks for the heater info. I'm away from home at the moment but I'll check when I get back. You are right about the top bolts. I had two M5 bolts * missing for the top hole. I also tried the M5 bolts from the cooling bag but these are actually for the header tank supporting beam (from memory). in the end I just used my own bolts. *i'm pretty sure that they were M5 anyway.

My progress has slowed as I'm now back at work. Sadly working gets in the way of important Caterham building.

A petty strut is a bar that goes from the roll bar to the bolt by the passenger door. I think it is a requirement for some sprinting events. It provides more security if something goes wrong. I wonder if a class may open for 160s in sprint events. I wouldn't mind a go if so. It might be a good way in, without scaring yourself witless in something with more power. The two pin plug I bought from eBay didn't quite fit (sadly). Although I have the male and female part so I may replace he whole plug. I'm not in a rush though. I thought about putting the power socket on the far left. However, I thought that the cable for the sat nav would flop over the passenger knees. I'm going to wait a bit before doing anything.

I managed to fit the radiator today. Nothing too difficult. However, I did get stumped by not recognising that to mount the fan on the radiator you need to slot in the little plastic right angled bolt holders. (Thanks Peter M) Very annoyingly I also managed to over tighten one of the radiator bobbin nuts and break the bobbin. I'll see if Caterham will send me another. 12v socket. It seems that under the dash there is a two pin socket (black, purple/red). There is also a fuse ready in the fuse box for a power supply. I intend to buy a connector and 12v socket (eBay?) and fit a 12v supply after the car gets through its IVA. (Again thanks Peter for starting me off). Petty Strut A friend advised me that it might be worth putting a centre punch mark where the petty strut bolts on to the passenger side (behind he aluminium). It can be awkward to locate later. I may use a petty strut at some stage, so I have done this - only a 5 min job. Sill Protectors It looks like the area under the doors gets quite a bit of abuse. I have ordered some carbon fibre sill prototectors from Carbon mods for about £40 a pair.

Ned: I gave the car a good dose of Dimitrol (around the engine bay and behind the fuel tank, under the boot). Seems pretty good stuff. (And felt a bit dizzy after using it in an enclosed space )

Ah preserving the wood had not occurred to me. I might have a go at that too. another thing to consider; putting a centre punch mark where the petty strut fits on the passenger side (there is a bolt hole behind the aluminium). I am told this makes it a bit easier if you ever want to fit a petty strut later on.

Ah yes, good thinking. I had quick look and yes, that is obviously what should happen (and Caterham haven't sent the wrong fan). I was wondering what the plastic bits were for. It doesn't look like a perfect fit but I'm sure it will work with a bit of encouragement. I'll try tonight. did you have any luck finding your power socket? I went head down in the footwell yesterday for a good look and I have definately got it (black and purple and red). For a couple of pounds I have also bought the matching socket from eBay (hopefully). If it fits I'll post the link. Once I get my car through the IVA I'll connect up the 12v socket. Caterham have even put a fuse in the fuse box ready for one. The only dilemma is where to put it.

Peter, i have just just tried to fit my radiator. however, I notice that the fan mounting holes and the radiator bolts are a long way off. Unless I'm being daft I think that it is the wrong fan. It might be worth checking yours. I also seem to be short of some of the nesassary nuts and washers for the radiator and intercooler. I have emailed caterham. Simon

I found a connector with a black and purple wire, with the right shape connector (as shown in the wiring diagram; two slots at 90degrees). it was in a difficult place to see, close to the main wiring loom under the dash on the passenger side in the heater area. thanks for this info, it is going to be handy for me. I hope you find yours.