Build Day 9- Prop Shaft, LSD, Radiator

Day 9- Prop Shaft, Clutch Hose, Limited Slip Differential and Radiator.

Cut Down Allen Key

To start off we, incredibly slowly, engineered the cut down Allen key needed for the gearbox filler plug, and also then found a use for the excess end. On our Duratec engine in our SV model there are 3/8" bolts going through the engine mounting arms and into the rubber mounts. As most people will also find there isn't a 3/8" Allen socket adaptor in any regular set without getting a completely separate set, so we used the excess end in a 3/8" socket to be able to adequately torque the engine bolts, which we immediately did.   

A good 30+ mins taking a hacksaw to this key...

Parts together ready for torquing.

Prop Shaft

This has got to have been the most frustrating thing so far... 
We slid the prop shaft in through the back and aligned in in the tunnel ready to connect it to the engine. After coating it with copper grease as required, me under the car and dad lifting from the top, we attempted to align the splines and connect the shaft. However after a short while of struggling we were still unsuccessful. 

From my perspective I thought the problem could've been that the gearbox shaft was turning, so we decided to install the gear stick so we can then lock the gearbox to stop the shaft in place. However after an hour of guessing how to attach the gear stick we eventually back to aligning the shaft, which was still to no avail. Up to this point we had been giving Caterham the benefit of the doubt as to have given us the correct part, but it eventually cracked and we measured the two parts with a pair of vernier calipers, only to find a 1.5 mm difference between the two. At this point we decided we had waisted enough time trying to establish whether it was the wrong part or whether I suck at using calipers and added it to the extensive list of things to try and get Caterham to clarify... 

We sent a pic of the shaft label to email for verification.

Clutch Cable

To de-stress for a little bit we decided to quickly fit the clutch hose to the clutch reservoir. There is already a connection in the top of the reservoir, however the connection already fitted through the banjo joint so we simply removed the quite purposeful looking part and connected the hose.  

Removal of fitted connection.

Actual connection method for the clutch hose.

To stop the hose being damaged on the edge of the pedal box we wrapped it with self amalgamating tape.

Radiator

Thus far with the radiator we have found that the slots in the side are too short and small to be able to get it over the roll bar and then have enough clearance to get the bobbins between the brackets and the cowling. The only help so far has been to refer to images of how its make in the factory, which clearly shows the hey hole shape cut into the cowling; and that Caterham themselves cut the slots, thus only raising the question of whether we have the right cowling or not, again... 

In the end we have decided to just remedy the situation our own way. We decided to use an old tool of my father's father, called a Lang/ Turner Nibbler, a device which cuts sheet metals of different thicknesses.

Nibbler, Just found it on Amazon for £85... glad we had one.

Just the promo video of the nibbler showing its capabilities. 

Marking out a small section, initial mocking up seemed quite close.

However first alteration not quite there yet...

Still only one side can be positioned.

Second alteration, making it look slightly more like the standard key hole shape.

Third alteration, gave in trying to make it a close fit and just made it look as similar to the factory version as possible. 

Finally all tightened up with, as always, a plain washer between the spring washers and the metal surface.

Summary shot of the car so far!!!

As I have written this a few days (Tuesday) after  actually completing this Derek has helpfully sent us the correct prop shaft which arrived earlier this evening. It is currently sitting in its box next to the even larger box containing the correct tunnel top. We can't help but estimate hundreds of pounds have been spent by Caterham getting these parts (plus others) to us in the post or by courier on next day delivery.