Build Images – September 2017 | A Caterham Seven Blog

Back in its box

Rolling the car out for the final time with no engine

Engine mount hex key is 9.5mm in new money

Gearbox very close to chassis member. Refused to budge.

The front of the engine gets really close to the front diagonal chassis member

Holding up the gearbox end

Ready to take the hoist back to Pete. Thanks Pete!

Gearbox mounts all torqued up

Aww! Rats! That didn’t work! Should have kept the plug in the end of the gearbox

Marking up the faces so I knew which faces I’d ground down

Captain Dremel

Grinding down a 12mm hex key to fit imperial engine mount bolt

Lunch was calling

Trolley jack added to support the back end of the gearbox

Just before we start on the main event

Leveler at the end of its useful travel

Wider angle view of the chassis and footwell protection

Protecting the footwells from coming into contact with a swinging engine

Removing the engine mount struts seemed to make the install go better

Leveller sits more in line with the engine but not quite perfectly so

Additional earthing point from battery to chassis insert on passenger footwell

Leveller with extensions added

Additional earth point – chassis insert in top left of this picture

Engine mount with earth lead loosely attached

Load leveller

Engine hoist in long configuration

Engine hoist in short configuration

Engine hoist

LH engine mount and earth lead attached

Quite a bit of the top radiator hose poking out of the front of the engine

Top hose with larger jubilee clip

Radiator top hose – “L”

Horns attached to steering rack cross member

Snipping cable tie restricting horn cable from reaching the space connectors on the horns

Electrical connections closer together. The bolt and spacer are also shown

Undoing the horn bracket

Front ARB bush mounted to front chassis with clamp

Front ARB inserted into upper wishbone and shroud covering the joint. Just need to snip off the ends of the cable-ties.

Upper wishbone ARB excess with powder coat removed.

Upper wishbone ARB recess after one attempt at fitting ARB. The powder coat on the front end of the recess came off easily, on both sides.

Ball on the end of the front ARB

Red front ARB bushes inserted into their clamps. Note I’m using WD-40 PTFE lubricant.

Washer bottle pipe coiled in boot and attached to full filler pipe.

Washer bottle tucked under radiator hose. Picture from recently built 420R at Williams

Washer bottle pipework and electrics connected through fuel filler shroud

Washer bottle mounted in boot

Washer bottle bracket mounted on off side boot body work

Dinitrol 3125 Corrosion Protection

Dinitrol 3125 sprayed into the curved lower bodywork in the engine bay. You can see the heatsheilding running all the way up to the body work – Grot Trap?

Front brake hose connects to front calliper with coupling and copper washer. The tapered end of the coupling is towards the hose.

Front brake hose connects to brake pipe with nut and star washer. Star washer next to the bodywork.

Final front brake hose assembly

Supplied brake hoses and couplings

Track rod end now set correctly to 13 turns for SV chassis

Track rod end not on far enough

Bottom upright joint. There’s a very small gap between the special nut and the lower wishbone

My prop keeping up the upright

My upright prop

19mm spanner can be used to wiggle the upright and give the caphead bolt a better chance of going in

Wobble bar and socket used to tighten upright top joint

Stool / Creeper

Top of near side front damper. The bolt is laborious

Joint of chassis, headlamp assembly and upper wishbone. You can see the lug on the headlamp stem that folds under the chassis at the bottom of the headlamp stem plate (I hope that makes sense)