Tips for Self Builders Please.

[Zagster]

Reading through the various build blogs it appears the manual isn't very good or comprehensive in some areas for example in the way to do things and in what order.

I wondered if we could put together a comprehensive list of tips to help the self builders as there appears to be quite a few mid way through projects or starting projects soon. For instance is it better to join the gearbox to the engine out of the car of put them together in situ!

In trying to compile tips I am looking at a few blogs with different engine specs so some of this may not apply to add to the confusion but it gives a warning!!

1. First tip, put the IVA edge trimming on before you put in the front suspension.

2. Dintrol/ACF-50/POR-15 water/mud traps etc inside of headlights arms also.

3. Handbrake cable - use washers to take up slack on the pin & put the clevis pin through the top & not bottom!

4. Diff -use a screwdriver in the top mounts, measure & fit the bottom bolts. copper slip top bolt and hit home.

5. Put gearbox oil in before installing in situ but plug the propshaft socket with a latex glove!

6. Rear hub axle - to align the 'A' frame & axle it's normally 4 washers on nearside & 3 offside!

7. Remove engine mounts from engine before you install

8. Get hold of proper popper tool for mats, boot cover etc as the one provided is useless.

9. fit propsahft first before engine goes in and get grease in it with grease gun.

10. 11 turns of the track rods to give approx track setting

11. Fit inner radiator cowl before anti-roll bar, it's located inbboard.

12. Need circlip pliers, copper slip, hose lubricant, hex adaptors and 9mmm hex drive.

Edited by Zagster on Monday 27th May 14:32

[Zagster]

Build blogs... anyone else got any?


https://www.facebook.com/pages/Caterham-7-Superspo...

http://racing13build.blogspot.co.uk/2009_10_01_arc...

http://www.caterham-build.co.uk/

http://home.btconnect.com/gwiddicombe/kitcar/july2...

Edited by Zagster on Monday 27th May 14:38

[Grubbster]

Add this to your list if you like

http://www.sevenracing.co.uk/Caterham_Build_Diary/...

And a load of photo's some of which might help

https://picasaweb.google.com/116424898161023374047...

[uremaw]

I'd be happy to keep a build diary/blog of my forthcoming build (20 days and counting!) but i suspect it would be counter productive, expletive-filled and without any realistic chance of success. Not much use unless you wanted a 'How not to build a Caterham 7' guide.

[sfaulds]

I'm intrigued as to what you think you'd need a 9mm hex bit for? I think it's about the only socket I own that's never been used.

[downsman]

Zagster said:

5. Put gearbox oil in before installing in situ but plug the propshaft socket with a latex glove!

8. Get hold of proper popper tool for mats, boot cover etc as the one provided is useless.

Filling the gearbox isn't as bad as people make out. I've cut a short piece off an allen key and use a ratchet ring spanner to tighten/loosen it with the car up on blocks. Using a short section of plastic tube the gearbox can also be filled from underneath by squeezing the Caterham oil bottles. I think filling the gearbox before installing the engine gearbox is a bad idea, and you'll still have to check the level is OK afterwards anyway.

The popper tool isn't good because you need three hands, and a piece of wood to use it.
There are nice tools out there but they cost the best part of £100.
I found some tube that was a good fit around the popper tool and welded that onto a G clamp using some 3mm steel as a spacer.
I then welded the other piece of the tool to the flat area on the G clamp so that when tightened the popper tool was pushed down into the centre of the cup area.
It was then easy to fit the poppers by just tightening the G clamp handle

I hope this makes sense, but e-mail me if you want a picture

[Zagster]

Thanks Grubbster, great blog, it all helps

Uremaw, I hope you do write a blog but if not any tips and clangers to avoid would be handy for us- good luck with your build, put some pics up when she arrives.

Sfaulds sorry you will have to go through the blogs to find out what the 9mm hex was for. I am only taking quick notes from them...

Thanks for that Downsman, not critical then on both counts, can be done. I have the the same problem by the sound of it on Land Rovers, you can buy a bottle with a plastic swan neck that fills up gearboxes etc from below. Think they are available from Frosts.co.uk