Saturday 17 March 2012

Day 3

With the prospect of a delivery of part from Caterham, I set aside another full day to try and get the car ready for the engine installation.

First job is the fixing of the rear brake pipes to the de dion tube. The de dion ears and calipers are fitted temporarily to allow correct fit up. Caterham supply the brake pipe partially pre bent but the final connection to the calip is left to do. once pop rivetted to the tube the brake pipe can be eased round in a smooth arc to the connection on each caliper.




Whilst waiting for the parts from Caterham I had a go at fitting the heater. I had heard this was fiddly but I didn't have too much trouble apart from some wiggling of the wiring loom behind the scuttle to get the interior vent panel in place. I couldn't find the two set screws needed but they are only short M5 screws so I'll find some that are suitable later.



Next up is the horns, an easy fit to the front cross member behind the steering rack.


Now armed with some heat shield material and carefully some patterns, I covered the drivers side footwell to try and reduce any heat build up from the exhaust manifold. I think I will have a look at the passenger side but I don't think this is really necessary, especially considering the plastic washer bottle is fitted that side and would melt before my feet!


Next we finished off the front end by fitting the anti roll bar and then lowering the car to try and get the front suspension settled before torquing up all the fastners. Finally the engine mounts were fitted ready for the next big job, engine installation!!

Friday 16 March 2012

Bits and bobs

What with work commitments and some missing parts I've not done much in the last few days, but have laid out all the parts for the de dion tube ready and made some patterns for the heat shielding of the engine bay. Thanks to Andrew for his tips to use Woolies Trim for the heat shield material.

Andrew also got me to check my front brake hoses and make sure they are for the wide track suspension and not narrow. I had not fitted both ends so didn't notice that they might be too short, but as suspected they are the wrong ones. Another email to Sean!


Thursday 8 March 2012

Day 2

LH shock finally installed after some wiggling and gentle filing of the fixings 
Upright and wing mountings added
Same on the RHS
Front end nearly finished, just  front ARB to fit!
Gearbox mated to bell housing

Monday 5 March 2012

The Build - Day 1


Propped up on axle stands with all the boxes at the back of the garage. Supersport engine in the foreground

Steering rack trial fitting


Steering rack installed with track rod ends ready to fit


Bodywork protection in place


Same on the right hand side


RH Wishbones in, but found that we had two LH headlamp brackets so had to stop this side as they need to be fitted to the to the top wishbone mounting


LHS nearing completion. We had lots of fun with the top shock mounting bolt, which still wont go in! A job for tomorrow I think!

The Big Arrival

The van arrives!
All ready to offload