Missing pages in the Caterham Build Manual, (sort of)
Discussion
I am half way through the count-down to the arrival of my kit, and I have had a thought. What things are missing from the Build Manual for the car?
By this, I am particularly thinking about steps I could or should be taking during the build process for corrosion protection of the chassis, but there may be many other things that I should be doing, but which won't be written down in the Manual.
What extra steps should I take during the build to have a better car in the future? It could be anything from a lockable box hidden somewhere on the chassis, to reversing a part to improve the ergonomics, or anything else for that matter.
Ideas?
Pip
By this, I am particularly thinking about steps I could or should be taking during the build process for corrosion protection of the chassis, but there may be many other things that I should be doing, but which won't be written down in the Manual.
What extra steps should I take during the build to have a better car in the future? It could be anything from a lockable box hidden somewhere on the chassis, to reversing a part to improve the ergonomics, or anything else for that matter.
Ideas?
Pip
I think that link is good start too.
For what it's worth, my advice would be to replace the missing pages with ones that say 'thinking time'
Take time to get to know your kit and do lots of dry assembly runs for each section first. The manual will be out of date so don't take it too literally and don't overdo the anti-corrosion - IMHO there's nothing worse than working on a car that is a greasy, waxy, gooey mess. Caterhams should be clean and shiny
Edit: Oh, and the 7 is the evolution of 50 years tweaking so don't change anything until you understand why it is that way in the first place.
For what it's worth, my advice would be to replace the missing pages with ones that say 'thinking time'
Take time to get to know your kit and do lots of dry assembly runs for each section first. The manual will be out of date so don't take it too literally and don't overdo the anti-corrosion - IMHO there's nothing worse than working on a car that is a greasy, waxy, gooey mess. Caterhams should be clean and shiny
Edit: Oh, and the 7 is the evolution of 50 years tweaking so don't change anything until you understand why it is that way in the first place.
Edited by DCL on Monday 23 January 08:58
I'm nearly finished building a 1.4 classic, I can magine how excited you are waiting for delivery day.
The top tips page already referred to has been very helpful.
I've picked these wise words up from someone along the way. The IVA supplement at the back of the manual is revised quite often so it is kept separate. It would be much better if it was integrated into the manual because some of the jobs would be easier if they were done when building that part of the car. So have a good read of the IVA section before starting.
The brakes do seem like a missing page. The front brake calipers used to come attached to the uprights ... they don't now so there isn't a page in the manual.
The rear brake calipers used to come in one piece (before the recent recall), now they come in pieces and it's a real jigsaw puzzle ... and no instructions.
The page for the new BMW differential isn't missing ... but it's not in the manual ... it's attached to the diff. THIS REALLY MATTERS ! The routing of the handbrake cable is completely different and cannot be put right without taking the diff back out.
When you insert the upper steering column you need to understand what's happening with the lower bearing. If you look UP the column tube from the engine bay you can see a white teflon bearing. This is VERY easy to push out of position or worse still PULL out of position if you pull the steering column back out. Put plenty of grease on the bearing and make sure there aren't any burrs on the steering column end. It's easy to get right once you see what's going on, but very easy to get wrong first time.
You might have heard tales of missing or wrong parts causing delays ... maybe they will but so far I have had just 1 grommet missing and Sean lived up to his reputation of same day despatch.
Someone else mentioned cups of tea. It really is amazing how impossible jobs become easy if you walk away and have a cup of tea.
We don't have any deadlines so every problem we encounter is fun to deal with. If we had deadlines to meet I doubt we would be enjoying it so much, so very very much !
The top tips page already referred to has been very helpful.
I've picked these wise words up from someone along the way. The IVA supplement at the back of the manual is revised quite often so it is kept separate. It would be much better if it was integrated into the manual because some of the jobs would be easier if they were done when building that part of the car. So have a good read of the IVA section before starting.
The brakes do seem like a missing page. The front brake calipers used to come attached to the uprights ... they don't now so there isn't a page in the manual.
The rear brake calipers used to come in one piece (before the recent recall), now they come in pieces and it's a real jigsaw puzzle ... and no instructions.
The page for the new BMW differential isn't missing ... but it's not in the manual ... it's attached to the diff. THIS REALLY MATTERS ! The routing of the handbrake cable is completely different and cannot be put right without taking the diff back out.
When you insert the upper steering column you need to understand what's happening with the lower bearing. If you look UP the column tube from the engine bay you can see a white teflon bearing. This is VERY easy to push out of position or worse still PULL out of position if you pull the steering column back out. Put plenty of grease on the bearing and make sure there aren't any burrs on the steering column end. It's easy to get right once you see what's going on, but very easy to get wrong first time.
You might have heard tales of missing or wrong parts causing delays ... maybe they will but so far I have had just 1 grommet missing and Sean lived up to his reputation of same day despatch.
Someone else mentioned cups of tea. It really is amazing how impossible jobs become easy if you walk away and have a cup of tea.
We don't have any deadlines so every problem we encounter is fun to deal with. If we had deadlines to meet I doubt we would be enjoying it so much, so very very much !
I was rather over eager when my first car arrived. I missed out the "miscellaneous" chapter out. Doing things like the screen washer and seats would have been a lot easier if the cage and engine/gearbox weren't in place
My advice would be, try not to worry and just enjoy it. You will make the odd mistake but they're all easy to rectify/work round
My advice would be, try not to worry and just enjoy it. You will make the odd mistake but they're all easy to rectify/work round
Replace the phillips head screws holding the fuel filter to the bulkhead with like-size hex head screws. That way, they can be loosened or removed far more easily without removing the seat, should you need to check or change the fuel filter.
This tip blatantly stolen from Myles at the very helpful Alcester Racing pages.
This tip blatantly stolen from Myles at the very helpful Alcester Racing pages.
The worst job during my build was drilling the (stainless) sill protectors. Do not follow the manual and drill though the holes in the inner skins because they will end up slots. Instead, mark up where to drill the sills using the holes in the inner skins, but do the drilling away from the car.
Well, I reckon that I only have two more weeks to wait for the delivery, give or take. Thanks for all the advice here and in the many other posts.
I have copies of the build manual sitting in the lav, an extra big box of PG Tips and I have been having a lot of fun buying tools and bits. Now I just have to finalise (i.e. do) the insurance, easier said than done, maybe, and actually get the boxes, chassis and motor delivered. Easy.
Now if only my weekends in April weren't quite so booked up...
I have copies of the build manual sitting in the lav, an extra big box of PG Tips and I have been having a lot of fun buying tools and bits. Now I just have to finalise (i.e. do) the insurance, easier said than done, maybe, and actually get the boxes, chassis and motor delivered. Easy.
Now if only my weekends in April weren't quite so booked up...
The word on the street is that Caterham finished my kit preparation yesterday, so hopefully it is only a week or so to go. It has taken a month longer than I was told at the end of last year, but now it makes sense to get the garage ready. I had been hoping to have the car ready to drive to the UK for the olympics, but that is not on the cards any more. Ho hum, I can just look forward to a few Autumn blats.
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