Caterham - How it's made

[gpwizard]

Hi all,

I'm new to the forum as I am researching the possibility of buying a 7 in the near future.

I haven't seen anyone post this video and I thought you all might be interested.


https://www.youtube.com/watch?v=gwhsAM7SW_0

[doclip]

Interesting video but annoying music

[Gingerbread Man]

doclip said:

Interesting video but annoying music

Too true. Nice watch though.

[militantmandy]

The metal tune is amazing but utterly inappropriate!

[IBDAET]

When did they buy Team Dynamics?

[nigelpugh7]

gpwizard said:

Hi all,

I'm new to the forum as I am researching the possibility of buying a 7 in the near future.

I haven't seen anyone post this video and I thought you all might be interested.


https://www.youtube.com/watch?v=gwhsAM7SW_0

Thanks for sharing that video, I have not seen that before anywhere!

It was great to see the new style wheels that I now have on my R500 being cast, painted and machined too., seems like we now know that they are definetly built by team dynamics as well!

Also very good to see several 620Rs in build stages too!

[scubadude]

Nice to see an up to date film too, often when companies allow this kind of thing its only for stuff that's far from their latest work.

As a graduate of a Manufacturing degree there where no surprises but nice to see plenty of manual manufacturing in the UK- where it should be :-)

[BBL-Sean]

This is the latest installment of the "How It's Made: Dreamcars" series for Discovery Channel/Science Channel; of Canadian origin. This Caterham 7 episode aired in the U.S.A. last week. I expect it should air in the U.K. some time soon on Discovery Channel, Discovery Science, or Quest. Check your local listings.

[mickrick]

Live axle? When did they start using those again?

[BBL-Sean]

mickrick said:

Live axle? When did they start using those again?

I believe that is the (modified?) Suzuki unit used in conjunction w/ the 660cc Suzuki engine and gearbox in the 160 model.

[moto_traxport]

BBL-Sean said:

mickrick said:

Live axle? When did they start using those again?

I believe that is the (modified?) Suzuki unit used in conjunction w/ the 660cc Suzuki engine and gearbox in the 160 model.

Definitely Suzuki axle on the 160 / 165 model to go with the Suzuki engine and 'box. Not sure how modified internally it is, I've been told it is upside down from it's original installation and possibly from a small van.

First post for me on Caterham sub forum thing.

[bertie]

Have to say I didn't know they assembled the engines.
I was certain they were crate jobs from Ford, so is that just the 620R engine they build maybe?

[stoneb09]

bertie said:

Have to say I didn't know they assembled the engines.
I was certain they were crate jobs from Ford, so is that just the 620R engine they build maybe?

My thoughts were the same - Was completely oblivious to the fact they construct them in house.

[DCL]

stoneb09 said:

bertie said:

Have to say I didn't know they assembled the engines.
I was certain they were crate jobs from Ford, so is that just the 620R engine they build maybe?

My thoughts were the same - Was completely oblivious to the fact they construct them in house.

IMHO that looks more like bespoke engine development work than anything else - I don't think you would measure the head volume on a production car engine, or grade the pistons for that matter, but maybe the 620R needs that sort of precision.

Nice to see some up to date footage though

[framerateuk]

I assume they have to do some work on them to get them pushing out enough power for some of the higher end models.

The 2.0 Duratec in standard guise puts out about 150bhp (or it certainly did in my Fiesta ST). To get 185bhp out of it needed new cams, air intake and a full exhaust (including manifold). I'm always surprised to read that the R300 and Supersport R run on standard cams - I'm not really sure how they do it!

[anonymous-user]

I thought Cosworth put the R400 and the SSR engines together?

[curley]

nigelpugh7 said:

Also very good to see several 620Rs in build stages too!

Especially when it's video of the engine and gearbox being fitted to your own car !

Gob smacked I was .

[ghibbett]

Interesting to watch, but blimey there's some errors in there! I think the writers for the narration need to learn their weld types! Also it just goes to show that the chassis is very basic to assembly from a Body-in-White perspective, but then again simple = light

Also interesting to know that the dash panel is stuck on with double-sided tape. Has anyone had much experience of removing these?

[Gingerbread Man]

ghibbett said:

Interesting to watch, but blimey there's some errors in there! I think the writers for the narration need to learn their weld types! Also it just goes to show that the chassis is very basic to assembly from a Body-in-White perspective, but then again simple = light

Also interesting to know that the dash panel is stuck on with double-sided tape. Has anyone had much experience of removing these?

My dash was stuck from the factory with silicone. I thought from watching that video that they siliconed it also and taped it tight till it set?

[ghibbett]

Looking at where they put the silicone/sealer, I would say it's function is pure sealing and that the Tape was doing all the adhering.

Was yours purely with sealer/adhesive?