Build Session #14 – To the inside

The internet is a wonderful help when building a Caterham. The number of blogs and forums provide a mine of useful information. One of the downsides, however is when you start re-reading them and discover something someone else did that you did not. In my case it was not putting the prop shaft bolts in with Loctite. Dominic Gregory describes that he did this too even using copper grease instead. As I read this in bed this morning I was thinking “we didn’t do that did we?” However when we got out to the garage to look, the tell-tale metallic brown goo was very much in evidence around the bolts. Dominic took his bolts out and cleaned all the copper slip off using a toothbrush and cotton buds. We discussed it and agreed that if we didn’t do likewise we would always know. So the first 2 1/2 hours of the day were spent removing each nut, cleaning it and it’s threaded hole then reinserting the bolt with Loctite. Only towards the end did I look in the manual and discover IT DOES NOT SPECIFY TO USE LOCTITE! Oh well at least our prop shaft should not work loose….

Crude, but effective method of bracing the propshaft..
Crude, but effective method of bracing the propshaft..
Drilling the breather bottle
Complete with hoses…

Next job this morning was to drill two holes in the breather bottle for the hoses. Miraculously I actually had to wood-boring drill bits of the correct size so we had the hoses is in place soon after. We cable tied them to the other cooling hoses as neatly and logically as we could. Then it was back to a couple of jobs from the to do list; fitting the gearlever, connecting the reversing light switch cables and tidying up the cables in the transmission tunnel.

We have decided to look at the carpets in the afternoon so went out to buy some contact adhesive after lunch in preparation. A few builders have recommended aerosol contact adhesive but we opted for spreadable to minimise the risk of getting glue where we did not want it.

Carpet jigsaw puzzle
Carpet jigsaw puzzle

We first glued the top, vinyl edge of the rear bulkhead carpet, using a wallpaper edge roller to press it into place. We left the rest unglued to allow the creases to drop out and also because we needed to torque up the top damper unit mounts which are covered by the carpet.

Wallpaper edge roller was never on the tool list...
A wallpaper edge roller was never on the tool list…

The boot carpets no longer come as one complicated shape but a series of smaller shapes fitting in space between the chassis members. One of us coated the boot with adhesive, whilst the other did the section of carpet and we worked our way round pressing each one into place. We removed the honeycomb floor above the fuel tank which made the curved side sections much easier to fit.

Boot floor lifted, but not removable.
Boot floor lifted to fit carpets, as it is not easily removable.

As well at the transmission tunnel carpets there were two other sections of carpet which looked like they should fit under the seats. However they were not cut correctly and we reckoned it was because of the lowered floor, which causes a step just next to the transmission tunnel. Time for another question to Derek; had we got the wrong carpets, or did we need to cut them to fit?

The final job of the day was to rivet the transmission tunnel top on.

More riveting.
More riveting.

This afternoon’s progress had really made us feel like we were well into the second half of the build, although the the number of rivet holes looking at us from the cockpit sides showed us we had quite a bit of work to do yet….

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