A Caterham Seven Blog
Putting the EV in sEVen – Index
Purplemeanie videos posted to YouTube
Bottom diff mountings needed 2 (LHS) and 3 (RHS) washers
Digital callipers used to work out how many spacing washers are needed.
Measuring diff carrier to box section the old way
Laser measuring distance from chassis box section to diff carrier
Blanking/skid plate in place.
Material trimmed from skid plate.
Sand off some material from the skid plate
That’s not right… there’s a hole that all sorts of stuff is going to get into
What was this?
Big screwdriver (top right) used to secure diff in top mountings. This will be the last useful job this screwdriver performs… read on for its finale!
Trolley extension piece :-). Gets used lots in the future.
The two top and two bottom mounting points
Diff ready to go in and trolley jack poised
Prop shaft finally fed into the gearbox. You can see one of the U shapes making up the universal joint.
Attempting to spread the transmission tunnel with a Maplin clamp
Throttle cable tensioned
Screwdriver used to bend accelerator pedal and tension the throttle cable
Duratec thermostat and housing in cross section
420R With Heater and Dry Sump – Water Circuit
420R With Heater and Dry Sump – Engine Bay Plumbing (from rear RHS)
420R With Heater and Dry Sump – Engine Bay Plumbing (from front LHS)
Caterham 420R Thermostat Overview – High Temperature Position
Caterham 420R Thermostat Overview – Low Temperature Position
Thermostat and housing (courtesy Caterham)
Airflow through radiator (RHS)
Heter control valve from inside driver’s footwell
Heater control valve shown from inside engine bay
And now on a torque wrench
32mm crows foot spanner in use
Crows foot 32mm spanner on a torque wrench with 1/2″ to 3/8″ converter – which actually got me exactly the spacing I needed.
Spanner needed to be 6+ mm
Heater control cable routes from the bottom left of this picture to the valve. Connections seemed easier with the battery removed.
Heater control valve in place and hoses connected
Made up a cable for the submarine earth lead connection
Crimp tool and components to make an earth connection for the submarine.
Submarine sits under the top radiator hose, next to its electrical connections coming out of the loom
Here’s the water T-piece installed
Water T-piece needs a short length of hose from it to the engine.
Passenger compartment vents installed with ear pointing downwards
Heater bolted in and retaining bracket included.
… and then into rear of cylinder head (note from the future – don’t do it this way)
… and then into rear of cylinder head
5/16th hose wraps around front of engine
Water Expansion Bottle sited with 5/16th” hose pointing backwards
Water Expansion Bottle bracket riveted in place. You can just see the elongated holes in the outboard (right) holes. The dremel slipped here – that’ll need some hamerite later.
Holes drilled for Water Expansion Bottle bracket. Aim was slightly off but near enough top of the rails
Regrease the ARB sockets
Add grommet to headlamp strut
Add grommet to chassis hole
Chassis bolt would hit the ARB if I hadn’t detached the ARB from its sockets and chassis mounts.
Pull the headlamp assembly away from the chassis
Off with the gator cable ties
Trying to post-fit a grommet into the hole where the cables exit the headlamp strut wasn’t going to work
Routing of oil pressure sender cable
Looking down LHS of engine bay – nowhere near finished yet
Looking down RHS of engine bay
Test fit of both bonnet and nose cone
Nose cone looking good
Loads of room between nose cone and water expansion bottle
Water expansion bottle bracket
Cutting the top radiator hose to length
Track day roll over bar in place
Holes don’t line up perfectly.
Additional bolt going up into roll over bar. You can see the upper mounting bolt for the rear damper in the top left of the picture
View of the top of the engine bay with radiators and oil hoses loosely in place
Oil hoses going into dry sump
View of oil hoses from underneath
And from the side
Now it looks a bit like this
Cleaning up the bat wing
Spring centre punch has been useful throughout the build
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