{"id":1267,"date":"2017-10-08T23:45:37","date_gmt":"2017-10-08T22:45:37","guid":{"rendered":"http:\/\/www.purplemeanie.co.uk\/?p=1267"},"modified":"2025-01-31T13:12:21","modified_gmt":"2025-01-31T13:12:21","slug":"build-session-23-harnesses-seats-and-silencer","status":"publish","type":"post","link":"https:\/\/purplemeanie.co.uk\/index.php\/2017\/10\/08\/build-session-23-harnesses-seats-and-silencer\/","title":{"rendered":"Build Session 23 : Harnesses, Seats and Silencer"},"content":{"rendered":"\n

An odds and ends day… but a big one… something to sit on!<\/p>\n\n\n\n

Having got the passenger compartment carpets installed is seemed only right to have a go at getting more of the finer things in life installed… harnesses and seats… Whoa we can move the seats out from the lounge!<\/p>\n\n\n\n

Transmission Tunnel Top<\/h3>\n\n\n\n

I had test fitted the transmission tunnel top a couple of times. It seems to be just be a friction fit – hmm… wonder if that\u2019s going to be a problem later?<\/p>\n\n\n\n

The back end of the tunnel top was a bit dinged up when I took it out of its poly bag. So out with the leather persuader this time and persuade it back into shape.<\/p>\n\n\n\n

\"\"<\/a>
Before persuasion<\/figcaption><\/figure>\n\n\n\n
\"\"<\/a>
Transmission tunnel top after persuasion<\/figcaption><\/figure>\n\n\n\n

Harnesses<\/h3>\n\n\n\n

Now onto the harnesses.<\/p>\n\n\n\n

For some reason I hadn\u2019t taken the harnesses out of their boxes until now. It was one of the things I\u2019d been looking forward to having a peek at and I\u2019m amazed I found enough to distract me from peering inside the boxes to this point.<\/p>\n\n\n\n

There wasn\u2019t much to find in the end. Exactly as I\u2019d hoped. I\u2019d heard stories of people getting mismatched colours and was relieved to find all was in order.<\/p>\n\n\n\n

The boxes came with instructions and the handed-ness was written on the box.<\/p>\n\n\n\n

Plonking the harnessing into the passenger compartment got me to the first uh-oh moment then. The handed-ness didn\u2019t make sense. When I put the harness marked LH into the passenger compartment the buckle with the big red lever was on the outboard side of the car. Same with the RH buckle, it was outboard. That\u2019s not right!<\/p>\n\n\n\n

All the builds I\u2019ve read about talk about needing to have the buckle towards the inside of the car. If you have the buckle outboard then people (probably including me) have a tendency to fling the buckle over the side of the car and dent, or scratch, the body work. That\u2019s not right.<\/p>\n\n\n\n

So, I made and executive decision and switched the harnesses around… buckle straps next to the transmission tunnel.<\/p>\n\n\n\n

The next job is to attach shoulder straps to the bolts set in the top chassis mounts. The harnesses have various bolts, washers and spacers included. There was also a poly bag sellotaped onto one of the boxes with Caterham supplied bolts included.<\/p>\n\n\n\n

I tried a couple of combinations of things and then settled on a solution. I needed a bolt (already inserted into the chassis when the car arrived), brass flanged spacer (hope that\u2019s a good name for it), aluminium spacer and flat washer. The kit also comes with a cardboard washer but that seemed to be superfluous.<\/p>\n\n\n\n

The brass flanged spacer sits the lowest in the stack. Then comes the aluminium spacer, harness strap, flat washer and then bolt.<\/p>\n\n\n\n

\"\"<\/a>
Harness shoulder strap fixing stack<\/figcaption><\/figure>\n\n\n\n

As you can see from the picture above. The brass spacer deforms as it is compressed. I tried a few experiements here and it seemed to me that the best approach was to tigheten the stack up without the harness included, which got the brass spacer inserted fully into the boot cover hole. I could then undo the bolt and fettle the brass spacer so the top flange looked less deformed ( I got it better than in the photo above). I could then refix the stack with the harness included and torque the whole thing up.<\/p>\n\n\n\n

There seems to also be an IVA related cap for the harness bolts. However, the caps are quite loose with my test fitting and so I\u2019ve left them to one side and will probably silicone them in place when I\u2019m convinced I don\u2019t need to take the harnesses out again.<\/p>\n\n\n\n

All in the harnesses look great.<\/p>\n\n\n\n

\"\"<\/a>
Passenger harness in place<\/figcaption><\/figure>\n\n\n\n

Seats<\/h3>\n\n\n\n

With both harnesses in place its time for some seats.<\/p>\n\n\n\n

Again… not a difficult job. First off I needed to get the carpets installed below the seats. I was in two minds about whether to glue the carpets in place or leave them floating. In the end I decided they are something that might get wet from time to time and so I didn\u2019t want them curling at the edges… so I glued them in place.<\/p>\n\n\n\n

That decision made I needed to make the holes in the carpets for the seat bolts. My solution was to lay the carpets in place and to mark the holes on the carpets with a paint pen from underneath.<\/p>\n\n\n\n

Then I could punch out the four holes with a 14mm punch tool.<\/p>\n\n\n\n

\"\"<\/a>
Punching holes in under seat carpets with 14mm punch<\/figcaption><\/figure>\n\n\n\n

And the carpets could be glued into place.<\/p>\n\n\n\n

\"\"<\/a>
Under seat carpets have holes punched into them<\/figcaption><\/figure>\n\n\n\n

Now the seats can be installed.<\/p>\n\n\n\n

The seat bolts poke through the bottom of the floors by a few mm past the nyloc nuts. However, it\u2019s important from an IVA perspective to A) have the bolts inserted from the top and B) the thread needs to poke out below the end of the nyloc nut. The first point is obvious, if the nyloc nut falls off then you still have a bolt semi-securing the seat in place. I\u2019ve come to appreciate the second point after reading a number of blogs where people have tried to cut short the bolts poking out of the nylon nut. ISTM that IVA inspectors want to see threads poking out of nyloc nuts so they can firstly see that the nylon is doing something and secondly the extra thread gives much greater scople for safety if you think the nut is going to come undone… it has to unwind itself by more threads before it falls off.<\/p>\n\n\n\n

Installing the seats was basically a simple task. Shoving the seat backwards to install the front bolts and then forwards to install the rear bolts is obvious. Getting the rear bolts tightened is another matter… I had all the 1\/4\u201d extension bars I could muster attached to a ratchet and Allen key socket. For me, I then wedged the wrench against something as I finally tightened up the nut from below with a spanner. On one seat the wedging meant that I had a real tug of war with the ratchet to unwedge it… but I got there in the end.<\/p>\n\n\n\n

Here\u2019s the end result. Almost looking habitable…<\/p>\n\n\n\n

\"\"<\/a>
Almost looking habitable<\/figcaption><\/figure>\n\n\n\n

Silencer<\/p>\n\n\n\n

One final job for the day… attach the silencer.<\/p>\n\n\n\n

Simple job and gets a big chunk of stainless steel and wadding out of my office. The detritus that makes up a kit is slowly assembling itself into a car!<\/p>\n\n\n\n

There\u2019s nothing much to report on the silencer going in. I had a few goes at tightening up the jubilee clip that fixes the silencer to that cat. I kept on tightening and the silencer still rotated it when I tweaked it. In the end I decided that it should rest with the outlet pointing slightly downward and I\u2019d have to revisit how tight the clip is if it leads.<\/p>\n\n\n\n

\"\"<\/a>
Silencer and cat shield installed<\/figcaption><\/figure>\n\n\n\n
\"\"<\/a>
Wow! This Purplemeanie\u2019s going to look great!<\/figcaption><\/figure>\n\n\n\n

That\u2019s another day done. Surely we\u2019re getting close to starting it?<\/p>\n","protected":false},"excerpt":{"rendered":"

An odds and ends day… but a big one… something to sit on! Having got the passenger compartment carpets installed is seemed only right to have a go at getting more of the finer things in life installed… harnesses and seats… Whoa we can move the seats out from the lounge! Transmission Tunnel Top I […]<\/p>\n","protected":false},"author":1,"featured_media":1277,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"advanced_seo_description":"","jetpack_seo_html_title":"","jetpack_seo_noindex":false,"jetpack_post_was_ever_published":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_publicize_message":"","jetpack_publicize_feature_enabled":true,"jetpack_social_post_already_shared":true,"jetpack_social_options":{"image_generator_settings":{"template":"highway","default_image_id":0,"font":"","enabled":false},"version":2}},"categories":[3,51],"tags":[33],"class_list":["post-1267","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-caterham-420r-build","category-caterham-blog","tag-build"],"jetpack_publicize_connections":[],"jetpack_featured_media_url":"https:\/\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/11\/7950015C-6B20-4879-A764-763321F6EC0D.jpeg","jetpack_sharing_enabled":true,"jetpack_shortlink":"https:\/\/wp.me\/p8yl38-kr","jetpack-related-posts":[{"id":942,"url":"https:\/\/purplemeanie.co.uk\/index.php\/2017\/10\/07\/build-session-22-scuttle-trim-knee-trim-panels-and-carpets\/","url_meta":{"origin":1267,"position":0},"title":"Build Session 22 : Scuttle Trim, Knee Trim Panels and Carpets","author":"John Martin","date":"October 7, 2017","format":false,"excerpt":"Whoa boy... you're getting ahead of yourself! At the end of the last post I said it was time to start thinking about starting the car. I \u201ccould\u201d... but... I'm still unhappy about putting fluids in the car and I clearly hadn\u2019t quadruple checked the quadruple checking I\u2019d been doing!...\u00a0I\u2026","rel":"","context":"In "Caterham 420R Build"","block_context":{"text":"Caterham 420R Build","link":"https:\/\/purplemeanie.co.uk\/index.php\/category\/caterham-blog\/caterham-420r-build\/"},"img":{"alt_text":"","src":"https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/10\/558FFE8E-B7C6-4B29-AC21-C8E6342CB23F.jpeg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/10\/558FFE8E-B7C6-4B29-AC21-C8E6342CB23F.jpeg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/10\/558FFE8E-B7C6-4B29-AC21-C8E6342CB23F.jpeg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/10\/558FFE8E-B7C6-4B29-AC21-C8E6342CB23F.jpeg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/10\/558FFE8E-B7C6-4B29-AC21-C8E6342CB23F.jpeg?resize=1050%2C600&ssl=1 3x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/10\/558FFE8E-B7C6-4B29-AC21-C8E6342CB23F.jpeg?resize=1400%2C800&ssl=1 4x"},"classes":[]},{"id":674,"url":"https:\/\/purplemeanie.co.uk\/index.php\/2017\/09\/02\/build-session-12-bonnet-delivery-gearbox-move-and-engine-bay-first-fix\/","url_meta":{"origin":1267,"position":1},"title":"Build Session 12 : Delivery, Gearbox Move and Engine Bay First Fix","author":"John Martin","date":"September 2, 2017","format":false,"excerpt":"Saturday morning and a chance to get a few hours in on the car. I'd not really had a chance to do anything since putting the engine in last Monday. I had managed to sneak into the garage late one night and fitted the gearstick and gear knob, but that's\u2026","rel":"","context":"In "Caterham 420R Build"","block_context":{"text":"Caterham 420R Build","link":"https:\/\/purplemeanie.co.uk\/index.php\/category\/caterham-blog\/caterham-420r-build\/"},"img":{"alt_text":"","src":"https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/10\/IMG_2020.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/10\/IMG_2020.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/10\/IMG_2020.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/10\/IMG_2020.jpg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/10\/IMG_2020.jpg?resize=1050%2C600&ssl=1 3x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/10\/IMG_2020.jpg?resize=1400%2C800&ssl=1 4x"},"classes":[]},{"id":448,"url":"https:\/\/purplemeanie.co.uk\/index.php\/2017\/08\/17\/build-session-3-tapping-a-poorly-threaded-harness-mount\/","url_meta":{"origin":1267,"position":2},"title":"Build Session 3 : Tapping a Poorly Threaded Harness Mount","author":"John Martin","date":"August 17, 2017","format":false,"excerpt":"A simple job today... when the car arrived there was an obvious problem with the inboard off side harness bolt. The car is set up for 4-point harnesses and it now seems that Caterham, not only pre-attach the hood and the boot cover, they also pre-drill and set up the\u2026","rel":"","context":"In "Caterham 420R Build"","block_context":{"text":"Caterham 420R Build","link":"https:\/\/purplemeanie.co.uk\/index.php\/category\/caterham-blog\/caterham-420r-build\/"},"img":{"alt_text":"","src":"https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/08\/Harness-Bolt-Sticking-Out.png?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/08\/Harness-Bolt-Sticking-Out.png?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/08\/Harness-Bolt-Sticking-Out.png?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/08\/Harness-Bolt-Sticking-Out.png?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/08\/Harness-Bolt-Sticking-Out.png?resize=1050%2C600&ssl=1 3x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/08\/Harness-Bolt-Sticking-Out.png?resize=1400%2C800&ssl=1 4x"},"classes":[]},{"id":735,"url":"https:\/\/purplemeanie.co.uk\/index.php\/2017\/09\/24\/build-session-18-prop-shaft-and-differential\/","url_meta":{"origin":1267,"position":3},"title":"Build Session 18 : Prop Shaft and Differential","author":"John Martin","date":"September 24, 2017","format":false,"excerpt":"Ok, so this post is a bit of a cheat. I actually put the prop-shaft and differential into the car yesterday... but it seemed to make sense to lump all these activities together in a single post. Accelerator Pedal Before we get to that though, and just to get me\u2026","rel":"","context":"In "Caterham 420R Build"","block_context":{"text":"Caterham 420R Build","link":"https:\/\/purplemeanie.co.uk\/index.php\/category\/caterham-blog\/caterham-420r-build\/"},"img":{"alt_text":"","src":"https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/09\/IMG_2572.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/09\/IMG_2572.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/09\/IMG_2572.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/09\/IMG_2572.jpg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/09\/IMG_2572.jpg?resize=1050%2C600&ssl=1 3x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/09\/IMG_2572.jpg?resize=1400%2C800&ssl=1 4x"},"classes":[]},{"id":850,"url":"https:\/\/purplemeanie.co.uk\/index.php\/2017\/09\/30\/build-session-20-handbrake-again-de-dion-dry-run-de-deon-fit-rear-arb-flexible-rear-brake-pipe-radius-arms\/","url_meta":{"origin":1267,"position":4},"title":"Build Session 20 : Handbrake Again, De Dion Dry Run, De Deon Fit, Rear ARB, Flexible Rear Brake Pipe, Radius Arms","author":"John Martin","date":"September 30, 2017","format":false,"excerpt":"After time for reflection over night and some blog reading... Handbrake Cable... Again Having seen a couple of pictures on other people's blogs, it was clear that the handbrake cable adjustment screws should be located in the clip on the RHS of the diff. I'm not sure what I was\u2026","rel":"","context":"In "Caterham 420R Build"","block_context":{"text":"Caterham 420R Build","link":"https:\/\/purplemeanie.co.uk\/index.php\/category\/caterham-blog\/caterham-420r-build\/"},"img":{"alt_text":"","src":"https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/09\/IMG_2749.jpg?resize=350%2C200&ssl=1","width":350,"height":200,"srcset":"https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/09\/IMG_2749.jpg?resize=350%2C200&ssl=1 1x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/09\/IMG_2749.jpg?resize=525%2C300&ssl=1 1.5x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/09\/IMG_2749.jpg?resize=700%2C400&ssl=1 2x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/09\/IMG_2749.jpg?resize=1050%2C600&ssl=1 3x, https:\/\/i0.wp.com\/purplemeanie.co.uk\/wp-content\/uploads\/2017\/09\/IMG_2749.jpg?resize=1400%2C800&ssl=1 4x"},"classes":[]},{"id":1613,"url":"https:\/\/purplemeanie.co.uk\/index.php\/2017\/11\/24\/build-session-35-front-wings-handbrake-cable-and-tidying-up\/","url_meta":{"origin":1267,"position":5},"title":"Build Session 35 : Front Wings, Handbrake Cable and Tidying Up","author":"John Martin","date":"November 24, 2017","format":false,"excerpt":"Day 3 of The Big Push - a Friday! I was hoping to get a lot done today but instead of a Big Push it turned into more of a Gentle Shove. Still... progress was made. 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