Started my Supersport R build
Discussion
Took delivery of the kit on Tuesday night and started the build on Wednesday. Making good progress so far, though the build manual is absolutely woeful. Half the time is spent trying to work out what the instructions actually mean and finding the relevant nuts/bolts. Some of the bags are clearly labelled, but others are just loose. Quite frustrating, but Derek at Caterham is an absolute legend. Very helpful and patient. Just wish I had his home phone number as his helpline shuts down at 4pm! 
Front suspension, steering, engine, gearbox and exhaust are all done. Having to work today so won't get much more done, but planning to fit the diff, axle, rear suspension and brakes on Sunday.
Anyone who's thinking about building one themselves, but maybe thinks it's too technical, just go for it. I've not done anything more complicated than changing a wheel before now. If I can do it, anyone can. Plus it's huge fun - frustrating at times, but immensely satisfying.
Anyone interested can checkout my very basic build diary on tumblr. I had planned to take hundreds of photos and videos to document the build, but once I got started, that quickly got forgotten.
Front suspension, steering, engine, gearbox and exhaust are all done. Having to work today so won't get much more done, but planning to fit the diff, axle, rear suspension and brakes on Sunday.
Anyone who's thinking about building one themselves, but maybe thinks it's too technical, just go for it. I've not done anything more complicated than changing a wheel before now. If I can do it, anyone can. Plus it's huge fun - frustrating at times, but immensely satisfying.
Anyone interested can checkout my very basic build diary on tumblr. I had planned to take hundreds of photos and videos to document the build, but once I got started, that quickly got forgotten.
Looking good! Hope to see you around when it is finished as i'm not too far away. Interested about the comments on blatchat about shock clearance. I thought the wide track used extensions on top of the shocks, but maybe that has been changed?
Good luck with the rest of the build.
David.
Good luck with the rest of the build.
David.
Edited by DCL on Saturday 29th June 14:46
My concern would be ground clearance. Your wishbones look pretty level (with the shocks fully extended) and if you are running 13 inch wheels then it'll be even lower. Don't be fobbed off by Caterham if you can't get the recommended ground clearance - it is important on the Scottish roads! If spacers are meant to be there and you are worried about undoing the nut, get them to replace the whole units.
Edited by DCL on Saturday 29th June 15:22
One of the classics was the water rail. The instructions say for a duratec, you should fit a small L-section pipe to the aluminium connecter at the rear of the engine block, then attach the water rail to the pipe. We spent an hour looking through every box trying to find either the L-shape hose and water rail. At this point i thought the build was going to have to go on hold for a few days as we couldnt fit the engine without the water rail, but I had an engine hoist that was due to go back the next morning, and my dad (who was helping out with the heavier jobs) wasnt available again till Sunday. I was absolutely raging at caterham for not providing the parts, and at myself for not checking they were there before i started.
Then i did a last ditch search through old posts on Blatchat and found that they'd discontinued the aluminium outlet ages ago due to cracking, and replaced the short L-shape pipe and water rail with a big long hose which had been packed in with the A-frame and dedion. I was delighted that the build could continue, but honestly - how long would it take to update the instructions to include this change? Less time than it's taken me to rant about it!
But for all the frustrations, it's still an amazing process. I'm sat here just in from 9hrs at work and all I can think about is nipping out for 'five minutes' to fit the handbrake and hoodsticks. But apparently i've got to spend some time with the kids. Harrumph...
Then i did a last ditch search through old posts on Blatchat and found that they'd discontinued the aluminium outlet ages ago due to cracking, and replaced the short L-shape pipe and water rail with a big long hose which had been packed in with the A-frame and dedion. I was delighted that the build could continue, but honestly - how long would it take to update the instructions to include this change? Less time than it's taken me to rant about it!
But for all the frustrations, it's still an amazing process. I'm sat here just in from 9hrs at work and all I can think about is nipping out for 'five minutes' to fit the handbrake and hoodsticks. But apparently i've got to spend some time with the kids. Harrumph...
The manual does have a lot to be desired 
.The problem they have is that the cars are in a constant state of flux, either due to spec changes, modifications, or parts availability. They do update the manual every now and then but it's soon out of date again. Best thing is to think of it as a generic guide and not gospel or specific to your car. If in doubt phone them!
Enjoy!
.The problem they have is that the cars are in a constant state of flux, either due to spec changes, modifications, or parts availability. They do update the manual every now and then but it's soon out of date again. Best thing is to think of it as a generic guide and not gospel or specific to your car. If in doubt phone them!Enjoy!
Looking very good. you seem to be making very rapid progress too. Given how things have been going, how long do you think its going to take you to complete it?
I realise its always difficult to remember sometimes what you've done when it comes to writing a new blog entry but info such as what you've already shared about things being different in the manual compared to reality would be invaluable additions to your blog and I'm sure would help out others who will follow it when they build theirs (guess whose about 2 months behind you )
Also, that blue tape looks really good. Is that just blue masking tape or something more serious. Tempted to purchase some whilst I remember.
Cheers and keep up the good work,
Tom
I realise its always difficult to remember sometimes what you've done when it comes to writing a new blog entry but info such as what you've already shared about things being different in the manual compared to reality would be invaluable additions to your blog and I'm sure would help out others who will follow it when they build theirs (guess whose about 2 months behind you
)Also, that blue tape looks really good. Is that just blue masking tape or something more serious. Tempted to purchase some whilst I remember.
Cheers and keep up the good work,
Tom
Yeah it seems to be progressing quicker than i expected, but this is partly down to me having an extra pair of hands for two of the three days. Meant we were only doing a side each for the front suspension, and it made the whole engine/gearbox install much simpler. My main piece of advice would be to recruit a helper!
I think also the fact that the the suspension and engine are very visible changes to the car make it look like it's progressing faster than it really is. I've no doubt there'll be entire days spent bleeding brakes/clutch, routing cables and tracing issues, with no visible progress whatsoever.
Yeah, you make a fine point about the manual issues. No point me moaning about them if I don't actually highlight whats wrong/unclear for others! I've been too knackered after 10+ hours in the garage to do much more than post some hastily grabbed photos so far, but i'll have a read back through the parts of the manual i've completed so far, and note down any of the areas i can remember having issues with. More than happy for you to contact me when you start your build if you want advice, as long as you sign a waiver acknowledging that i'm an idiot and anything I say is very probably wrong.
Got the tape in B&Q. Was stupidly expensive for masking tape, but it was the only stuff that was apparently ok to leave on paintwork for up to 30 days. I'm dying to take it all off now the front end is mostly done, but sods law says i'd end up scratching it 2 minutes after i do...
I think also the fact that the the suspension and engine are very visible changes to the car make it look like it's progressing faster than it really is. I've no doubt there'll be entire days spent bleeding brakes/clutch, routing cables and tracing issues, with no visible progress whatsoever.
Yeah, you make a fine point about the manual issues. No point me moaning about them if I don't actually highlight whats wrong/unclear for others! I've been too knackered after 10+ hours in the garage to do much more than post some hastily grabbed photos so far, but i'll have a read back through the parts of the manual i've completed so far, and note down any of the areas i can remember having issues with. More than happy for you to contact me when you start your build if you want advice, as long as you sign a waiver acknowledging that i'm an idiot and anything I say is very probably wrong.
Got the tape in B&Q. Was stupidly expensive for masking tape, but it was the only stuff that was apparently ok to leave on paintwork for up to 30 days. I'm dying to take it all off now the front end is mostly done, but sods law says i'd end up scratching it 2 minutes after i do...
I built a 140 Supersport recently and had a whale of a time - it was an itch I have wanted to scratch for all of my adult life. It was much easier than I expected (which ironically has lessened the otherwise huge sense of achievement a bit).
As discussed ad nauseum, the built manual leaves a lot to be desired - as it is a .pdf file (I didn't receive a printed version) it should be easy to make minor adjustments regularly (or have multiple versions or supplements for the variety of engines, options etc) and also to replace the photos with higher resolution colour ones based on a vehicle with a better contrasting body colour. I used a printed guide and had a laptop with the document open (and Blatchat!) so I could zoom in those photos I couldn't make out.
Any inadequacies of the manual are negated by the superb help, advice and reassurance that Derek provides. It would have been a significantly more frustrating job without him at the end of the phone or answering my frequent emails.
He also provides a no-quibble immediate shortage rectification service. "No-quibble" as it also covered bits I couldn't find due to my incompetence rather than their absence, though I did lots of bits missing
Derek tipped me off about building the headlamp sub-assemblies alongside the front suspension, bonding the cycle wings for a nicer look and using a clamp tool (rather than the hammer/punch thingy) for the various weather gear poppers but didn't tell me about filling the gearbox oil ahead of installation (doing that and getting the plug back in is three hours of my life I'll not get back) and the diff-icult installation is well documented...
There were also various "oh, ignore the manual; do it like this" conversations that in retrospect are amusing but were frustrating at the time but overall, the rest was pretty straight forward (engine installation especially: only 20 mins - the only job I had help for - to guide the gearbox into the tunnel as a I lowered/pushed the hoist; the rest was entirely my own work).
And don't get me started on the timing of my Post-Build chack, the subsequent IVA failure and necessary gearbox replacement... The people at Caterham are friendly, diligent and helpful but there does seem to be a lack of processes and/or controls that negates the delight of their cars.
That all said, these things to me are a rite of passage into 7-ownership and part of the initiation! No pain, no gain! Even after only a few weeks, it is *my* car in a way that nothing I've ever bought has been.
As discussed ad nauseum, the built manual leaves a lot to be desired - as it is a .pdf file (I didn't receive a printed version) it should be easy to make minor adjustments regularly (or have multiple versions or supplements for the variety of engines, options etc) and also to replace the photos with higher resolution colour ones based on a vehicle with a better contrasting body colour. I used a printed guide and had a laptop with the document open (and Blatchat!) so I could zoom in those photos I couldn't make out.
Any inadequacies of the manual are negated by the superb help, advice and reassurance that Derek provides. It would have been a significantly more frustrating job without him at the end of the phone or answering my frequent emails.
He also provides a no-quibble immediate shortage rectification service. "No-quibble" as it also covered bits I couldn't find due to my incompetence rather than their absence, though I did lots of bits missing
Derek tipped me off about building the headlamp sub-assemblies alongside the front suspension, bonding the cycle wings for a nicer look and using a clamp tool (rather than the hammer/punch thingy) for the various weather gear poppers but didn't tell me about filling the gearbox oil ahead of installation (doing that and getting the plug back in is three hours of my life I'll not get back) and the diff-icult installation is well documented...
There were also various "oh, ignore the manual; do it like this" conversations that in retrospect are amusing but were frustrating at the time but overall, the rest was pretty straight forward (engine installation especially: only 20 mins - the only job I had help for - to guide the gearbox into the tunnel as a I lowered/pushed the hoist; the rest was entirely my own work).
And don't get me started on the timing of my Post-Build chack, the subsequent IVA failure and necessary gearbox replacement... The people at Caterham are friendly, diligent and helpful but there does seem to be a lack of processes and/or controls that negates the delight of their cars.
That all said, these things to me are a rite of passage into 7-ownership and part of the initiation! No pain, no gain! Even after only a few weeks, it is *my* car in a way that nothing I've ever bought has been.
Very impressed Scott!
I'm slowly learning about my own Caterham after fixing/upgrading several parts over the past few months, but I'd love to build one. Once I have a proper garage with enough room on each side I'll have to scratch that itch!
The only part that frightens me is the wiring! Best of luck with the rest of the build, I'll be keeping an eye on your tumblr feed!
I'm slowly learning about my own Caterham after fixing/upgrading several parts over the past few months, but I'd love to build one. Once I have a proper garage with enough room on each side I'll have to scratch that itch!
The only part that frightens me is the wiring! Best of luck with the rest of the build, I'll be keeping an eye on your tumblr feed!
Scott
I posted ahead of reading your blog... you're making stunning progress!
re PBC and IVA timings... that was an error on my part - I waited until I had a feeling of a completion date ahead of booking these and then had a month-long wait to fit in with Caterham's and VOSA's schedules!
So get those in the diary ASAP!
Are you doing the IVA yourself or getting Caterham to?
I posted ahead of reading your blog... you're making stunning progress!
re PBC and IVA timings... that was an error on my part - I waited until I had a feeling of a completion date ahead of booking these and then had a month-long wait to fit in with Caterham's and VOSA's schedules!
So get those in the diary ASAP!
Are you doing the IVA yourself or getting Caterham to?
Thanks guys.
I'm going to contact the local IVA centre tomorrow to get a feel for waiting times. I'm currently thinking i may forgo the PBC, as the appointed garage in Scotland is a 120 mile round trip away. The cost of transporting the car there and back would easily pay for an IVA retest. Im thinking I could always try and claim my free PBC once the car is registered and road legal.
Yeah progress has been much better than I expected, but it's mainly down to me having my dad around for half of the build so far. Having two pairs of hands makes everything so much easier. My aim was always to build it with him, as my interest in (or obsession with) Caterham stems from being taken to umpteen kit car shows when i was a wee boy. He always wanted to build a seven himself, but my siblings and I kinda put paid to that. It feels great to be able to realise that dream now - very cheesy but true. He's also been asking how much it would cost for a basic caterham kit, so i'm hoping this may spur him into getting one himself, and I can help him build it!
tomwoodis - i've started work on the list of confusing, ambiguous or just plain BS parts of the build manual with regard to the R. Will post it up on the blog as soon as its done. How long till yours arrives?
I'm going to contact the local IVA centre tomorrow to get a feel for waiting times. I'm currently thinking i may forgo the PBC, as the appointed garage in Scotland is a 120 mile round trip away. The cost of transporting the car there and back would easily pay for an IVA retest. Im thinking I could always try and claim my free PBC once the car is registered and road legal.
Yeah progress has been much better than I expected, but it's mainly down to me having my dad around for half of the build so far. Having two pairs of hands makes everything so much easier. My aim was always to build it with him, as my interest in (or obsession with) Caterham stems from being taken to umpteen kit car shows when i was a wee boy. He always wanted to build a seven himself, but my siblings and I kinda put paid to that. It feels great to be able to realise that dream now - very cheesy but true. He's also been asking how much it would cost for a basic caterham kit, so i'm hoping this may spur him into getting one himself, and I can help him build it!
tomwoodis - i've started work on the list of confusing, ambiguous or just plain BS parts of the build manual with regard to the R. Will post it up on the blog as soon as its done.
How long till yours arrives?uremaw said:
Thanks guys.
I'm going to contact the local IVA centre tomorrow to get a feel for waiting times. I'm currently thinking i may forgo the PBC, as the appointed garage in Scotland is a 120 mile round trip away. The cost of transporting the car there and back would easily pay for an IVA retest. Im thinking I could always try and claim my free PBC once the car is registered and road legal.
Yeah progress has been much better than I expected, but it's mainly down to me having my dad around for half of the build so far. Having two pairs of hands makes everything so much easier. My aim was always to build it with him, as my interest in (or obsession with) Caterham stems from being taken to umpteen kit car shows when i was a wee boy. He always wanted to build a seven himself, but my siblings and I kinda put paid to that. It feels great to be able to realise that dream now - very cheesy but true. He's also been asking how much it would cost for a basic caterham kit, so i'm hoping this may spur him into getting one himself, and I can help him build it!
tomwoodis - i've started work on the list of confusing, ambiguous or just plain BS parts of the build manual with regard to the R. Will post it up on the blog as soon as its done. How long till yours arrives?
Many thanks, thats excellent news, that really would be a massive help I'm sure.I'm going to contact the local IVA centre tomorrow to get a feel for waiting times. I'm currently thinking i may forgo the PBC, as the appointed garage in Scotland is a 120 mile round trip away. The cost of transporting the car there and back would easily pay for an IVA retest. Im thinking I could always try and claim my free PBC once the car is registered and road legal.
Yeah progress has been much better than I expected, but it's mainly down to me having my dad around for half of the build so far. Having two pairs of hands makes everything so much easier. My aim was always to build it with him, as my interest in (or obsession with) Caterham stems from being taken to umpteen kit car shows when i was a wee boy. He always wanted to build a seven himself, but my siblings and I kinda put paid to that. It feels great to be able to realise that dream now - very cheesy but true. He's also been asking how much it would cost for a basic caterham kit, so i'm hoping this may spur him into getting one himself, and I can help him build it!
tomwoodis - i've started work on the list of confusing, ambiguous or just plain BS parts of the build manual with regard to the R. Will post it up on the blog as soon as its done.
How long till yours arrives?Assuming Caterham stick to their own timings I should have the kit first or second week in August. This being the case, I'm going to try and put in a significant amount of work before the winter arrives and it gets really cold out in the garage. My aim will be to get the car IVA'd for next spring. If I can exceed that then great but I don't want to rush it particularly.
Following your advice I'm going to pop down to B&Q/Home Base at the weekend and see If I can find the product you bought. No doubt it will be 3 times the price of what you can get it for online! A box turned up at work this afternoon with a few bits I've purchased ahead of time to make life easier:
- Electricians tape
- Dinitrol (are you using anything similar to protect the chassis?
- AC-50
-Ratchet Spanners
-Cable ties
-etc
So excited
One more question too if you don't mind. I see from your blog that you've got the Diff in. I was looking at the (LONG) thread on Blatchat the other day all about the Diff Carriers that have failed etc. I understand a fix was well underway from Caterham and was due to be fitted to existing cars sometime in July/August.
Not being an expert in the differences between them, do you know off hand which version they gave you in your kit? I;m obviously keen to get the most up to date version.
Cheers
Tom
Not being an expert in the differences between them, do you know off hand which version they gave you in your kit? I;m obviously keen to get the most up to date version.
Cheers
Tom
My kit was delivered on 15 March - I started building in the coldest period of the year (circumstances meant I did the reverse of most people and built the car during working hours and went nowhere near the garage in evenings or at weekends!) I have a photo taken from under the car of snow pelting down outside!
You can see the multiple layers of clothes and hat (I never wear hats unless in extremis) I wore early days in this time lapse video (~360x real time):
http://www.youtube.com/watch?v=6CJVA8jQ0SE&sns...
Setting up the camera was a spontaneous decision; if I thought, I'd have realised the majority of work is done around the engine bay and so aimed the camera there. Ho hum! Enjoy (if you've ~20mins to spare!)
You can see the multiple layers of clothes and hat (I never wear hats unless in extremis) I wore early days in this time lapse video (~360x real time):
http://www.youtube.com/watch?v=6CJVA8jQ0SE&sns...
Setting up the camera was a spontaneous decision; if I thought, I'd have realised the majority of work is done around the engine bay and so aimed the camera there. Ho hum! Enjoy (if you've ~20mins to spare!)
Stuff i've used so far (as well as a decent socket set) :-
- Copperslip (lots of)
- Metric and imperial spanners (mainly use metric so the imperial ones are just cheap non-ratchet ones)
- Ball-head allen keys - imperial and metric
- Hex sockets (I needed a 9mm one for the engine mount bolts - had to source it online)
- Torque wrench - i got a cheap Sealey 7-112nm one from amazon for £32 and it's perfect
- Hand riveter
- Metric and imperial HSS drill bits
and most importantly...
- a soft faced hammer
- Copperslip (lots of)
- Metric and imperial spanners (mainly use metric so the imperial ones are just cheap non-ratchet ones)
- Ball-head allen keys - imperial and metric
- Hex sockets (I needed a 9mm one for the engine mount bolts - had to source it online)
- Torque wrench - i got a cheap Sealey 7-112nm one from amazon for £32 and it's perfect
- Hand riveter
- Metric and imperial HSS drill bits
and most importantly...
- a soft faced hammer
The new diff carrier is said to be imminent (as it has been for a while!)... so worth insisting you get one.
When I confirmed my order early in the New Year, I thought I'd got that covered, and asked and got what I thought was confirmation that I'd get the new one but in retrospect the email from the salesman was ambiguous - I saw what I wanted to see rather than what he was saying!
When I confirmed my order early in the New Year, I thought I'd got that covered, and asked and got what I thought was confirmation that I'd get the new one but in retrospect the email from the salesman was ambiguous - I saw what I wanted to see rather than what he was saying!
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