Build Day 35- Throttle Cable, Brake and Clutch Bleeding, and Reg Plate Light

Day 35- Throttle Cable, Brake and Clutch Bleeding, and Reg Plate Light    

Throttle Cable 

We have decided not to do as instructed and bend the throttle pedal, and follow the advice of my Cousin, who used to work for Arch Motors constructing Caterham chassis' and has since worked on many Caterham rebuilds and repairs. His advice, as he had done this many times, was to remove the plastic from a chocolate block connector and and clamp the metal clam to the throttle cable either side of the pedal. 

We cut the end off, passed it through the hole, then connected one block before then two after.

Brake Bleeding

This is fairly easy but time consuming, and requires 2 people, unless one has an Eezibleed kit. Did this as instructed in the order:

1. Left Rear
2. Right Rear
3. Left Front, Inside
4. Left Front, Outside
5. Right Front, Inside
6. Right Front, Outside

This was going well until we managed to get air in the system from not topping up the fluid regularly enough. We did find that taking a rubber mallet to the callipers did wonders for dislodging pockets of are trapped in parts of the calliper. This was all going to plan up until the third circuit, where we ran out of fluid, so had to stop there.

Our Apparatus

We found that these surgical clamps were useful in reducing spillage of the brake fluid.

We have also bled the clutch, which was very hard without a proper bleeding tool (with the cut out in the hollow socket tool, allowing for the tube to pass inside the tool onto the bleed nipple. However we did manage to use a pair of needle nose pliers to give enough grip to close the nipple enough to then remove the hose and not create a leak.

Registration Plate Light

On our car the earthing for the light didn't seem adequate enough so we improvised our own. We started by removing the bracket the light sits on, then created a strap which passes from the self tappers to the light fixing. After attaching the light plate the bracket was re-attached and the power cable fed through the back of the bracket.

Earth strap fitted.

All slack pulled through. This is not required as we don't have the wheel carried option.

The power wire was cut to length then the bullet connection was crimped on the end and connected.

Light fitted with the fog and reverse light, and the fuel filler cap, which had all been removed for the application of the PPF.

Finally a finished layout for the coolant pipes, with all sensors and earth straps attached.