Day 13: more plumbing, intercooler, radiator, header tank

After a weekend off, I was itching to get back on the car this evening. Apart from the steering column, the front end of the car is now complete, which is a great feeling.

Header tank fitted, and connected up. Mysteriously, the Assembly Guide is very keen on inserting clips onto the degas hose (think de-gas, not Degas the artist), but doesn't actually instruct you to connect them up to the header tank itself.

I fitted the intercooler as instructed. But... my chassis is slightly proud in the middle of the cruciform weld. As a result, the middle of the intercooler does 'ground' onto this. To save any bent aluminium, I put another spacer washer underneath, to lift it another 1/8" or so.

All the main pipes to and from intercooler and radiator are very easily sorted, and very satisfying. Though without my set of hose clamp pliers, the job would be very tricky I'm sure.

Finally, a bit more cable tying and now the only thing to be connected up are the battery cables.

Everything connected, apart from battery terminals

I couldn't resist fitting the front wheels

Day 12: front brake hoses, header tank bracket, rollover bar, general plumbing & cable tidying

A really productive day today. Chris from the Dartford factory came over to fit the rivnuts for my header tank bracket, which had been left off in manufacturing. Although I thought I could do i I'm very glad he came over nevertheless.

Once the header tank support bracket was fitted, I could move on and complete the rest of the cooling system. BUT... I think Chris might have gone home with the tank bracket itself (the small golden coloured plate that fits onto the cross piece). Ah well... another email to Derek.

Chris generally looked over the car, and was extremely complimentary and helpful, giving me a lot of insider tips, which I shall try and put down here. He builds these cars for a living, after all.

1. Front brake hoses

The Assembly Guide is hopeless here. But here is how the Caterham mechanics do it:

 a) everything you need will be in the Goodrich brake bags, apart from the 3/4-3/8 flat washer from the front suspension pack. Nice feeling!

b) the brass washer must be seated evenly. If it's not properly seated, the brakes will leak

c) nicely seated, and tightened up with ring spanner

d) this is the order that the cable fits from inside out: locknut, spring washer, aluminium skin (where my thumb is), flat washer from suspension bag (on the outside of the aluminium skin), nut, fitting on the braided hose

e) fit the hose so that the natural curve goes out horizontally and then points towards the back of the car

f) hose tailing nicely towards the rear of the car

g) making sure that the hose is not twisting at the skin end, and holding in the middle of the hose between thumb and forefinger (not shown here) pick up the outboard end and turn towards the caliper

h) taking firm hold of the narrow locknut to stop the hose twisting any more, screw the hose into the caliper fitting. If you get this right, you get the curve perfect

j) this is how it should look. No chance of hitting the damper, or any other bits of the suspension

Lastly, the brake pipe is located onto the end of the fitting pushed through the skin, and everything is tightened up with the brass-coloured nut

I hope this is helpful to other builders.

2. Then, onto general plumbing:
- hoses between heater and engine
- hoses between engine and radiator
Without the header tank, I can't finish off, but there enough there to get everything neatly tidied up and clip what's necessary to the frame.

All electrics are tidied left and right, and under the ECU, apart from the main battery cables, which are still floating free 

3. Lastly, the rollover bar, which went on with no problems.

I like my mahogany-looking bit of plywood in the boot :-)