Build finished. Now for the niggles...
Discussion
First the good news.... the build is complete, the car has passed the German version of the MOT (not a trivial undertaking) and the car is registered and on the road.
There are two minor issues, and I would like to know if they are common.
1) There is a very small leak from the five speed gearbox (from the join close to the back). Is this common? Can it be fixed? Does it involve removing the engine? It is only a very small amount, but it isn't a good sign on a new box. The oil runs forward from the join and then drops onto the floor further forward than the point where it leaks. If this is a big thing to fix, I dread to think how to coordinate it for a kit built outside the UK.
2) The speedo is not accurate -- not even close at high speeds. I need to go out with a passenger (with notebook) and a GPS to see if it is a linear offset or if the speedo is accurate at low speeds, but then tails off at higher speeds.
And as an aside, it is amazing that these items didn't impact on the inspection....
There are two minor issues, and I would like to know if they are common.
1) There is a very small leak from the five speed gearbox (from the join close to the back). Is this common? Can it be fixed? Does it involve removing the engine? It is only a very small amount, but it isn't a good sign on a new box. The oil runs forward from the join and then drops onto the floor further forward than the point where it leaks. If this is a big thing to fix, I dread to think how to coordinate it for a kit built outside the UK.
2) The speedo is not accurate -- not even close at high speeds. I need to go out with a passenger (with notebook) and a GPS to see if it is a linear offset or if the speedo is accurate at low speeds, but then tails off at higher speeds.
And as an aside, it is amazing that these items didn't impact on the inspection....
pipnjones said:
First the good news.... the build is complete, the car has passed the German version of the MOT (not a trivial undertaking) and the car is registered and on the road.
There are two minor issues, and I would like to know if they are common.
1) There is a very small leak from the five speed gearbox (from the join close to the back). Is this common? Can it be fixed? Does it involve removing the engine? It is only a very small amount, but it isn't a good sign on a new box. The oil runs forward from the join and then drops onto the floor further forward than the point where it leaks. If this is a big thing to fix, I dread to think how to coordinate it for a kit built outside the UK.
2) The speedo is not accurate -- not even close at high speeds. I need to go out with a passenger (with notebook) and a GPS to see if it is a linear offset or if the speedo is accurate at low speeds, but then tails off at higher speeds.
And as an aside, it is amazing that these items didn't impact on the inspection....
Useful thread on Blatchat? : http://www.blatchat.com/t.asp?id=220527There are two minor issues, and I would like to know if they are common.
1) There is a very small leak from the five speed gearbox (from the join close to the back). Is this common? Can it be fixed? Does it involve removing the engine? It is only a very small amount, but it isn't a good sign on a new box. The oil runs forward from the join and then drops onto the floor further forward than the point where it leaks. If this is a big thing to fix, I dread to think how to coordinate it for a kit built outside the UK.
2) The speedo is not accurate -- not even close at high speeds. I need to go out with a passenger (with notebook) and a GPS to see if it is a linear offset or if the speedo is accurate at low speeds, but then tails off at higher speeds.
And as an aside, it is amazing that these items didn't impact on the inspection....
Can't help with the 2nd point though.
I'm assuming this is a Sigma or Duratec engined car? Is the speed drive from a wheel sensor or gearbox output? In either case then it sounds as if the speedo needs to be set to the appropriate wheel circumference.
On the first issue, where exactly do you think the oil is coming from as it often drips down from the lowest gearbox point. Oil leaks from the gearbox to bellhousing join are quite common if sealant/gaskets are not used in the right place (then quite a lot of luck also required!)
On the first issue, where exactly do you think the oil is coming from as it often drips down from the lowest gearbox point. Oil leaks from the gearbox to bellhousing join are quite common if sealant/gaskets are not used in the right place (then quite a lot of luck also required!)
Funnily enough, the speedo has sorted itself out (mysteries never cease). I went out today for a blat in the lovely sunshine and checked the speedo again and it is okay up to 140 kph. If I am above this, I am either speeding anyway or on derestricted Autobahn trying to keep my fillings in and being eternally amazed by how blurred the rear view in the mirror is when there is that much vibration. But to fill in the holes, it is a measurement off a toothed ring on the rear axle and the engine is a Sigma engine.
The oil leak is coming from a join between the gearbox and a little extension bit on the back of the gearbox, and is not dribbling back from the bell housing seal at the front (thank goodness, because I would have felt a kipper if it had been meandering backwards). Apparently the gearbox extension is a piece that adds the fifth gear to the gearbox. I have done a bit over 250 miles now so I will be going through the car checking that everything is still tight (there is a small clicking noise that appeared today that you only hear when moving, not idling for example), tightening the wheel nuts, etc. I will then work through the gearbox area again, take photos and get in touch with Caterham.
The nice thing is that now I know the speedo is OK, I can take off the steering wheel and rotate it 2-3 degrees anticlockwise and reaffix it, and also fix the padding onto the middle of the steering wheel so the cabin is 100% complete.
I also had a good reminder to check everything two or three times (with tea in between) before grumbling too much. I thought I had been losing paint on the bonnet around the air vents. I could see white "expose filler" (as if I have lost some of the base coat). But on closer inspection, I think it is white residue that has stuck to the slightly warm surface. But I am not 100% sure and will be giving it a once over with a wet cloth to see if the "base coat adhesion problem" can be made to magically disappear....
The oil leak is coming from a join between the gearbox and a little extension bit on the back of the gearbox, and is not dribbling back from the bell housing seal at the front (thank goodness, because I would have felt a kipper if it had been meandering backwards). Apparently the gearbox extension is a piece that adds the fifth gear to the gearbox. I have done a bit over 250 miles now so I will be going through the car checking that everything is still tight (there is a small clicking noise that appeared today that you only hear when moving, not idling for example), tightening the wheel nuts, etc. I will then work through the gearbox area again, take photos and get in touch with Caterham.
The nice thing is that now I know the speedo is OK, I can take off the steering wheel and rotate it 2-3 degrees anticlockwise and reaffix it, and also fix the padding onto the middle of the steering wheel so the cabin is 100% complete.
I also had a good reminder to check everything two or three times (with tea in between) before grumbling too much. I thought I had been losing paint on the bonnet around the air vents. I could see white "expose filler" (as if I have lost some of the base coat). But on closer inspection, I think it is white residue that has stuck to the slightly warm surface. But I am not 100% sure and will be giving it a once over with a wet cloth to see if the "base coat adhesion problem" can be made to magically disappear....
pipnjones said:
...I can take off the steering wheel and rotate it 2-3 degrees anticlockwise and reaffix it...
You lost me there. To dial out the steering wheel being off centre, you would normally adjust the track rod ends not the wheel. For large changes, you can slipa spline on the steering column UJ near the rack.HTH
Martyn
pipnjones said:
and also fix the padding onto the middle of the steering wheel so the cabin is 100% complete.
I took the padding off as soon as I got my car tested. Probably you get a nicer pad, but the one supplied with UK kits is horrible, and the harnesses should stop contact with it 
Shame about your leak. I've had two diffs with leaks from the input oil seal.
I checked how much I needed to top up the second one and it is only using 10ml in 1500 miles, so I've decided to leave it.
It'll help stop corrosion on that part of the chassis
Steering adjustment logic... steering rack is fine, the universal joint is square for symmetrical steering feel. I removed the steering wheel and the safety boss to replace a faulty tacho, and when I put it back on, it was a click clockwise from where it should be, so it is easy to fix. It is less hassle than adjusting it nearer the front of the car.
Yes, the Caterham cover for the middle of the steering wheel is a bit of a dog, but I will see what I can do. With enough of the rubber cut off the back it should fit. I have the Momo original, too, so I can choose. Maybe I will use one on Monday-Wednesday, and one on Thursday-Sunday....
Yes, the Caterham cover for the middle of the steering wheel is a bit of a dog, but I will see what I can do. With enough of the rubber cut off the back it should fit. I have the Momo original, too, so I can choose. Maybe I will use one on Monday-Wednesday, and one on Thursday-Sunday....
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