Build Day 25- Side Screens, Knee Trim, and Sill Protectors.

Day 25- Side Screens, Knee Trim, and Sill Protectors.

While I had been away on my oil Tanker Course dad had been fiddling and had managed to wrap our  

Side Screens

First we attached the hinges onto the windscreen using the black bolts, black domed nuts, black washers and some loctite to hold it together. (On this part be careful with the bolts as the heads are very easy to gouge out with allen keys so use minimal hand torquing) Then we put masking tape down the leading edge of the RH side screen, lined the screen up with the hinges and marked the drill holes with a pen. This is tricky as the holes comes very close to the edge of the internal metal frame, when trying to get the back of the screen to align concentrically with the rear wing. 

Aligning the side screen.

Cleaning out the screen.

After drilling the holes we cleaned out the swarf, with a paper clip, from under the vinyl exterior. Finally we gingerly attached the rest of the hinges to the door and fitted it to the car.  

We then intended to move onto the other door, however when we unwrapped the other screen we discovered that it was a scuffed second hand one that had been drilled already. We will have to get Caterham to send us a new one as soon as possible. The second hand one can go onto the pile of things that are going back to Caterham at the post build inspection.

Knee Trim and Sill Protectors

Before any of the interior panels can be riveted the sill protectors and the knee trim panels have to be fitted. We started at the front and worked our way backwards, firstly by inserting the knee panels then marking the holes as the pre drilled ones, as all have discovered, are nowhere near being in the right place.

Panel holes centred and clamped ready for drilling. 

When going to fit the panels we decided to fit them using self tappers instead of rivets so we would later have the opportunity to remove the windscreen if and when we buy an aeroscreen.

Tappers in and rubber trim sandwiched in-between the body and the side panels.

We continued to put the self tapping screws in until they reached adjacent to the scuttle edge, then moved onto fitting the carbon sill protectors. First we ran a length of masking tape along the bottom edge of the deeper side of the protector. Then held it in place with the front edge in line with the rear corner of the scuttle, and marked the holes for drilling. After drilling the holes we did the same with the armrest catch having aligned it with armrest pin. 

Surprisingly tough to drill these little bits of stainless.

Sill in and looking great, thankfully we remembered to fit the rubber trim. To fit the rubber trim we drilled holes through in transit so as to guarantee the tautness of the trim.  

Riveting finished. As we don't have the other screen we can't move on to the other side.

Speed Sensor

While Dad finished the riveting I decided to fit the speed sensor. In order to protect the cable we covered it with heat shrink, then installed it in the bracket. Hopefully it will work properly as others have had trouble with it in the past. 

Shrinking to fit.

Hopefully this is enough gap between the sensor.

Heater Hoses

To finish the evening we had a quick tinker with the layout of the hoses as there are many things that restrict the layout.

The 'J' Hose on the right had to go over the top and pinned thus otherwise the shape would kink thus restricting flow. The submarine T piece has to go upside down due to the long end of the T piece not fitting inside the P-clip, and because the earthing lead not being long enough to actually reach the lug anywhere else. The P clips are just being used in order to remove kinks. This is made worse by the fact that trying to get the T piece any close puts a kink in the hose coming from the heater control valve, no matter how we arrange the hoses.