Finished . . . well very nearly
Discussion
Finished . . . . well nearly. Just got a couple of bits to add, like exhaust manifolds (being done next week), diff braces, new tunnel top and then press the start button on the new engine . . .
It was one of BaT's hire cars, I stripped it to bare chassis after convincing myself I'd just use it as it was for a while (my wife laughs at this as she knows me too well) and then upgrade as I went, rather I stripped it and completely re-built it to a different spec over the last 12mths . . .
I did print off the assembly guide and thanks to Mickrick for a couple of bits of advice, but otherwise I learnt as I took it apart and used the manual as reference when required. BaT do really look after their cars, Arch confirmed the chassis was straight and unmolested (2006 SV), then the slow process of re-building.
I'm sure many will question the sanity, but who wouldn't do it given the chance and time. I couldn't find a car I wanted in the classifieds and Jonny made me a proposal that gave me the base kit I wanted and then from there it developed, grew, morphed and changed a bit more.
Why an SV . . . Well here's me in the passenger seat at Cadwell in an S3. I just don't fit easily and as I'm not racing what's the point of making myself fit, easier especially with passengers etc to go SV - which of course presents a range of other issues. Yes I'm ready for the fat gags, but being long in leg, broad and powerfully built means it'd been like driving a coffin, but with less space.
There's many solutions I didn't like, so have changed or am changing, such as the god awful wiring, dials and instruments as far as the eye can see, with DTH TB's the vertical throttle cable solution, so I have a modified version ready to go on sourced through a Speedway supplier, the connection to the fuel rail after Jenvey installation, I know I could buy the Jenvey fuel rail, but I'll have to look at it, ECU's in the engine bay with all the associate wiring . . Most mods have come about because off other mods, or because I just didn't like the compromise solution. The scuttle is fully removable, all the wiring and ECU's are hidden against the bulkhead without further fastenings through there othere than the catch tank etc . .
I really enjoyed the freedom to improve that this project gave me. Would I do it differently next time . .. Of course
Overall a great project, great car to work on, and I'm happy with the finished product, just now need to learn to drive it properly on track, so that's this years project, refreshing my rather rusty driving skills.
How it did look . . .
Along the way . .
Some nearly finished pics . .
Sorry, but unlike others I'm crap at capturing the turn of each n ut and bolt with an SLR in brilliant detail. Credit to the build bloggers, but I just used the mobile phone when I remembered. Although I did loads of shots as we took it apart.
Spec
2006 SV chassis
DVA engine (all the normal toys with forged pistons, pipers, worked on VVC head etc, Jenvey DTH TB's, balanced etc)
Custom loom
Quaife QB26 sequential, refreshed with all later mods - yes the older version
Quaife LSD, refreshed
Race Technology Dash2 and DL1
Emerald K6
Geartronics Flatshift - not yet installed
Nitrons
Poly bushed throughout
Diff braces from force racing
Exhaust silencer - Raceco, manifolds 'Exhaust by design'
Carbon nose, aero screen + mirrors, front and rear wings, dash and half doors
Tonneau cover in ally
OMP 4.25ltr plumbed in system
That covers the most of it, but these lists never articulate the detail and time to do properly . .
Thanks go our to Dave Andrews, Bruce at Arch, Ammo at Raceco, Mickrick and Carl at Sevenspeed who've all been either helpful or quick to reply and despatch parts, knowledge or support.
Other suppliers I am less inclined to do the same from the Caterham community.
Caterham cars would save thoughsands if they could send the right parts the first time . ..
This is all more important when you're doing this living in France, where the number of suppliers is significantly restricted and your french language is equally limited!
Hope you like it, I'm sure many will say why not Duratec. Well because I like the K and when I do eventually go Duratec it'll be for a power hike, with Sadev probably in a couple or 3yrs. I deliberatly went to one of the best K experts for the engine build to remove the concerns.
SV cos I'm powerfully built. Nitrons cos I got a great deal at the show and my other were going for service. Race technology as the package from the show was too good versus the others, carbon because I could, so I did, FIA roll bar because it is how it came, I'll go full Cage over the next winter probably .. . Some choices suit, so keeping the handbrake as our drive is more than 1 in 4 helps etc . . Also if I wanted to get it onto the road, less aggro etc. .
What do you think? Did I do an alright job, pictures never really tell a detailed story, but I think I did alright. Budget wasn't limitless at all and that's one reason it took 12mths. I'd appreciate peoples views as I know we would all do it differently and I accept the condition of the car will only deteriorate being a track car, but accept that as part of the deal ..
It was one of BaT's hire cars, I stripped it to bare chassis after convincing myself I'd just use it as it was for a while (my wife laughs at this as she knows me too well) and then upgrade as I went, rather I stripped it and completely re-built it to a different spec over the last 12mths . . .
I did print off the assembly guide and thanks to Mickrick for a couple of bits of advice, but otherwise I learnt as I took it apart and used the manual as reference when required. BaT do really look after their cars, Arch confirmed the chassis was straight and unmolested (2006 SV), then the slow process of re-building.
I'm sure many will question the sanity, but who wouldn't do it given the chance and time. I couldn't find a car I wanted in the classifieds and Jonny made me a proposal that gave me the base kit I wanted and then from there it developed, grew, morphed and changed a bit more.
Why an SV . . . Well here's me in the passenger seat at Cadwell in an S3. I just don't fit easily and as I'm not racing what's the point of making myself fit, easier especially with passengers etc to go SV - which of course presents a range of other issues. Yes I'm ready for the fat gags, but being long in leg, broad and powerfully built means it'd been like driving a coffin, but with less space.
There's many solutions I didn't like, so have changed or am changing, such as the god awful wiring, dials and instruments as far as the eye can see, with DTH TB's the vertical throttle cable solution, so I have a modified version ready to go on sourced through a Speedway supplier, the connection to the fuel rail after Jenvey installation, I know I could buy the Jenvey fuel rail, but I'll have to look at it, ECU's in the engine bay with all the associate wiring . . Most mods have come about because off other mods, or because I just didn't like the compromise solution. The scuttle is fully removable, all the wiring and ECU's are hidden against the bulkhead without further fastenings through there othere than the catch tank etc . .
I really enjoyed the freedom to improve that this project gave me. Would I do it differently next time . .. Of course
Overall a great project, great car to work on, and I'm happy with the finished product, just now need to learn to drive it properly on track, so that's this years project, refreshing my rather rusty driving skills.How it did look . . .
Along the way . .
Some nearly finished pics . .
Sorry, but unlike others I'm crap at capturing the turn of each n ut and bolt with an SLR in brilliant detail. Credit to the build bloggers, but I just used the mobile phone when I remembered. Although I did loads of shots as we took it apart.
Spec
2006 SV chassis
DVA engine (all the normal toys with forged pistons, pipers, worked on VVC head etc, Jenvey DTH TB's, balanced etc)
Custom loom
Quaife QB26 sequential, refreshed with all later mods - yes the older version
Quaife LSD, refreshed
Race Technology Dash2 and DL1
Emerald K6
Geartronics Flatshift - not yet installed
Nitrons
Poly bushed throughout
Diff braces from force racing
Exhaust silencer - Raceco, manifolds 'Exhaust by design'
Carbon nose, aero screen + mirrors, front and rear wings, dash and half doors
Tonneau cover in ally
OMP 4.25ltr plumbed in system
That covers the most of it, but these lists never articulate the detail and time to do properly . .
Thanks go our to Dave Andrews, Bruce at Arch, Ammo at Raceco, Mickrick and Carl at Sevenspeed who've all been either helpful or quick to reply and despatch parts, knowledge or support.
Other suppliers I am less inclined to do the same from the Caterham community.
Caterham cars would save thoughsands if they could send the right parts the first time . ..
This is all more important when you're doing this living in France, where the number of suppliers is significantly restricted and your french language is equally limited!
Hope you like it, I'm sure many will say why not Duratec. Well because I like the K and when I do eventually go Duratec it'll be for a power hike, with Sadev probably in a couple or 3yrs. I deliberatly went to one of the best K experts for the engine build to remove the concerns.
SV cos I'm powerfully built. Nitrons cos I got a great deal at the show and my other were going for service. Race technology as the package from the show was too good versus the others, carbon because I could, so I did, FIA roll bar because it is how it came, I'll go full Cage over the next winter probably .. . Some choices suit, so keeping the handbrake as our drive is more than 1 in 4 helps etc . . Also if I wanted to get it onto the road, less aggro etc. .
What do you think? Did I do an alright job, pictures never really tell a detailed story, but I think I did alright. Budget wasn't limitless at all and that's one reason it took 12mths. I'd appreciate peoples views as I know we would all do it differently and I accept the condition of the car will only deteriorate being a track car, but accept that as part of the deal ..
Edited by Johno on Monday 7th January 15:07
Look forward to seeing you out on track in it. 
Thanks Jeremy, it'll be good to see your 7 again, its been some years since I was driving on the same track at the same time. You will obviously be faster, a lot faster, but I'll watch your lines after you go passed me.
Thanks CFK, thanks, it's an advantage of not needing to equip it for the road. I tried to keep it as symmetrical as possible as well. After fire ext handle, cockpit kill switch, start button, gear pos indicator and a bloody big oil pressure warning light nothing else is needed. The buttons on the right control the Dash2 with the central button being for the high intensity rear light (not really needed at a trackday, but j.i.c for other reasons one day maybe).
Thanks CFK, thanks, it's an advantage of not needing to equip it for the road. I tried to keep it as symmetrical as possible as well. After fire ext handle, cockpit kill switch, start button, gear pos indicator and a bloody big oil pressure warning light nothing else is needed. The buttons on the right control the Dash2 with the central button being for the high intensity rear light (not really needed at a trackday, but j.i.c for other reasons one day maybe).
mickrick said:
Very nice. Nice attention to detail.
Don't know what I did
But glad I could be of help
Thought you'd forget Don't know what I did
But glad I could be of help Just a couple of pieces of advice via email and directing me towards Force Racing and Bruce at Arch, I think the specific question was about drive shaft removal originally. .
The steering wheelis a compromise to be able to see the shift lights more easily, if I don't get on with it I will change and add an additional shift light onto the scuttle with a round wheel. However with a quick rack and watching back the videos of last driving the car at Spa I didn't need to move my hands apart from potentially La Source from the 10 to 2 position, even when it wasn't doing as I'd planned
All the carbon except for the front wings came from MOG Racing, who were very good, despatched quickly and the quality is good enough for me. Again, being based in Paris the costs of delivery have an impact and likely damage, so easier to source from Germany.
As for numbers from the engine, we'll have to see, spec as below . . . Should be good for high 180/190 maybe 200
Jenvey TBS matched to head
Full port on head
Omega forged pistons
Piper BP285H cams
Airbox
Full balance at Vibration free
Lightweight flywheel
Verniers
Modded rods
Goetze liners
VVC blanking kit
EU2 injectors
Peen and skim head
Polish crank
All the carbon except for the front wings came from MOG Racing, who were very good, despatched quickly and the quality is good enough for me. Again, being based in Paris the costs of delivery have an impact and likely damage, so easier to source from Germany.
As for numbers from the engine, we'll have to see, spec as below . . . Should be good for high 180/190 maybe 200
Jenvey TBS matched to head
Full port on head
Omega forged pistons
Piper BP285H cams
Airbox
Full balance at Vibration free
Lightweight flywheel
Verniers
Modded rods
Goetze liners
VVC blanking kit
EU2 injectors
Peen and skim head
Polish crank
Edited by Johno on Tuesday 8th January 12:42
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