{"id":1635,"date":"2017-11-25T23:59:58","date_gmt":"2017-11-25T23:59:58","guid":{"rendered":"http:\/\/www.purplemeanie.co.uk\/?p=1635"},"modified":"2025-01-31T13:11:20","modified_gmt":"2025-01-31T13:11:20","slug":"build-session-36-repeaters-iva-mirrors-wipers-rear-hubs-wings","status":"publish","type":"post","link":"https:\/\/purplemeanie.co.uk\/index.php\/2017\/11\/25\/build-session-36-repeaters-iva-mirrors-wipers-rear-hubs-wings\/","title":{"rendered":"Build Session 36 : Repeaters, IVA, Mirrors, Wipers, Rear Hubs, Wings"},"content":{"rendered":"\n

Day 4 of The Big Push – Phew! This is getting tiring! I’m glad I decided I needed to take some time off to get this knocked out. While I’m not getting as much time on the car as I hoped, I am making progress. All that’s going to change today… no distractions, no excuses!<\/p>\n\n\n\n

Front Wings Again<\/h3>\n\n\n\n

Today, I wanted to at least get to the point where I had the Carbon Fibre Wings “tacked” onto the Wing Stays.<\/p>\n\n\n\n

As far as I know the only hard and fast regulations around the front wings are the IVA trim needed around the edges of the wings (done) and the requirement that the leading edge of the wing has to be forward of a line drawn vertically at the front edge of the wheel (not tyre).<\/p>\n\n\n\n

On this second point I have read blogs, and seen emails from Caterham, where they recommend the leading edge of the wing is 75 mm from the wing stay. That’s a good starting point but seems a little vague to me. It’s fine in the factory where they know what has been done to the car already but in a home-garage, where I’ve been tweaking and bending the wing stays, I could have inadvertently moved the wing stays fore or aft. In the correspondence I’ve seen it’s also not obvious whether that recommended measurement is to the front of the wing stay or the centre line. It’s much easier to measure to the outside front of the wing stay, so I assume that’s what they’re referring to. So, anyway, my recommendation is still to set up a plumb line of some sorts and verify that the wing will sit forwards of the wheel.<\/p>\n\n\n\n

To this end, I sat a wing onto a wing stay and used  a large set-square I had kicking around to make sure the wing was in front of the leading edge of the wheel. I then measured from the front of the wing stay to the front of the wing (including IVA trim). ISTM that a little extra distance would satisfy my fear of getting this wrong, so I set my measure at 80mm (8cm) and marked it with masking tape…<\/p>\n\n\n\n

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Leading edge of front wings set to be 8cm (80mm) from front of wing stay.<\/figcaption><\/figure>\n\n\n\n

Next up was to try out the routing of the repeater wiring. I’d extended the earth lead of each repeater a couple of days previously so could try fitting them.<\/p>\n\n\n\n

My repeater\/wing install consisted of the following:<\/p>\n\n\n\n

  1. Insert pull cord through wing stay – a thin piece of coated wire in my case<\/li>
  2. Add approx 15cm of 7mm heatshrink to the wires nearest repeater<\/li>
  3. Thread repeater heatshrink\/wires through 16mm hole I’d cut in the wings<\/li>
  4. Thread heatshrink\/wires through wing stay (using pull cord)<\/li>
  5. Add grommet to wires and insert where wires exit wing stay<\/li>
  6. Add long piece of 7mm heatshrink to wire ends<\/li>
  7. Insert heatshrink through grommet added to wing stay (using lubricant to get the heatshrink as far in as possible)<\/li>
  8. Apply heat to heatshrink<\/li>
  9. Bond wings to wing stays<\/li>
  10. Cable-tie wires to rear arm of top wishbone<\/li>
  11. Bolt earth lead to chassis (there’s a threaded hole on both sides where the front t-piece is bolted on both LHD and RHD cars)<\/li>
  12. Wire repeater signal wire into the econoseal connector<\/li><\/ol>\n\n\n\n

    Here’s a few pics of some further tidbits…<\/p>\n\n\n\n

    A paper-clip worked better than tweezers at getting the pull cord out of the wing stay…<\/p>\n\n\n\n

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    Paper-clip worked better than tweezers<\/figcaption><\/figure>\n\n\n\n

    Tape the repeater wires to the pull cord…<\/p>\n\n\n\n

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    Repeater wires taped to pull cord<\/figcaption><\/figure>\n\n\n\n

    I removed some material from the back of the grommet I used for the wiring exit from the wing stay. This allowed the grommet to go in more easily, especially as I’m feeding two wires down the tube where Caterham only do one…<\/p>\n\n\n\n

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    Modified my grommets to make them easier to insert<\/figcaption><\/figure>\n\n\n\n

    I did a test run again without the wings in the stack…<\/p>\n\n\n\n

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    Dry-run of repeater wiring again<\/figcaption><\/figure>\n\n\n\n

    Ok. So at this point it was still early in the day and I was being nervous about attaching the wings to the wing stays while having to work around the car all day – I might knock them as I move around. I still have 4 days until the PBC (Post Build Check) and so could afford to wait until the end of the day to stick the wings onto the stays.<\/p>\n\n\n\n

    Onto something else then…<\/p>\n\n\n\n

    Engine LHS Wiring Tidy-up<\/h3>\n\n\n\n

    Next up was to spend a couple of hours (2:15 to be precise) sorting out the wires one the LHS of the engine. I’m happy that I don’t have anything that’s going to mean I need to pull this apart again, so time to tie it all down for IVA.<\/p>\n\n\n\n

    There’s a few things going on with the wiring under the intake manifold:<\/p>\n\n\n\n