Frustrating steering installation

This is definitely not the most annoying thing about this built, the shortages have been far more annoying but some how this has really got my back up.

Yesterday I followed the instructions and fitted the lower steering column. Over night I realised that, having torqued it up as per the documented request, I would need to remove the bottom of the lower column. This would allow me to set the orientation of the steering wheel. There are no other options with the quick release wheel. So again poor instructions.

So today I thought I would spend my precious evening fitting the upper column and wheel centralise it and torque it up for good. The points below outline the steps I took, try to see where I became frustrated.

1. Lubricate and insert top bush - easy

2. Grease upper column and slide through both top and bottom bush

       - top bush bit of wiggling but ok

       - bottom bush won't go through

3. Scratch head 

4. Realise it is not the bottom bush but the lower column that it has to go over. (the lower column needs to slide inside the upper column and both slide inside the bush) It must be a bit misaligned.

5. As I will have to remove the clamp at the bottom of the lower column, I might as well do it now. I will be able to align them outside of the bush before sliding both in.

6. Slide out top column from bottom bush

7. Slide out lower column

8. Align and insert lower into outer.

9. Humm! It doesn't seem to fit.

10. Remove both from car.

11. Inspect upper - looks ok

12. Inspect lower - hum, it has a bit of a lip on it, probably form when it was parted.

13. No problem - out with file to remove lip.

14. It still doesn't fit - out with vernier

Diameter of end of shaft

Inner diameter of upper

Huston we have a problem, or more specifically an interference fit. With a bit of heat I am sure I could get it in but it would never come apart again.

So rather than continuing to file,  which would mean losing round ness and corrosion resistant coating I have decided I might let Derek send me a new lower.

Prop to diff, primaries, catch tank and lower steering column.

I have done a few little bits over the last few days

Prop to diff

It was a bit fiddly but after a the first one I got the knack of it and the rest were easy. I put loctite on them all and torqued to 60 Nm

Next up was the primaries, but before fitting them I could not resist taking a picture down each exhaust port.

I hope not to have to look down these again.

Primaries fitted next

Again quite straight forward to fit.

I wanted to fit the oil tank next but am missing a few bolts and p clips so it will have to wait. I did however, install the catch tank and it's bracket.

The only other thing I have now done is the lower steering column. (Sorry most of the photos are dark the lights in my garage are poor and most work is done in the evening.

Not without good reason

Not with out good reason.......is aligning, or rather inserting the top bolt in, the diff known as the hardest job. I nearly swaged three spacers in to the top LH bush, but after some precision engineering it is aligned to a the tightest tolerance the measurement uncertainty on my measuring instruments would allow. +-0.5 mm

For good measure I also removed the BMW shafts and stuck in the caterham ones

The only other thing I managed today was to replace the gearbox support bolts with the correct ones that Derek had sent them over.

Engine and diff

Sorry for not posting for a few days, I have been working on the car but Clare took the ipad and updating on either iphone or laptop seem to be less fun than working on the car.

Building engine hoist

I protected the engine bay with cardboard.

And spent sometime working out how the gearbox support fits. Unfortunately the bolts were missing but rather than wasting the time I had set aside I borrowed some from another pack and sent an email to Derek so I can swap them with the correct ones later.

I then spent ages joining the gearbox to the engine

I was now ready to go!

Time lapse video - I am not sure how to load it.

Having installed the engine I saw this great big hole - straight into the bell housing. A quick phone call to Derek and he has sent the sump protector over that blocks the hole.

Having fitted the gearbox I could not resist the temptation to fit the gear lever.

After the success of the engine it was on to single handedly fitting the diff. It was easier than it sounded.

Handbrake

I have not done much in the last couple of days, to busy with work and family life. 

I did manage to get in the garage and torque up my front brake lines having had reassurance from blatchat after my last blog entry.

I have also fitted the hand brake.

I have put it in the lowest setting to try and ensure that it can't be caught on the cuff of a glove when changing gear. This was a fear I always had with my last caterham.

Brake lines

Not sure if this is correct but it is the only way that makes sense to me. The manual doesn't mention the lock nut but shows instead a plain washer.

Prepping for engine install

Firstly a big thanks to Derek at Caterham for all the packages I have been receiving.... It's like Christmas.

Over the last couple of nights I have been prepping for the engine installation, including:

Cutting down the end of an Allen key to glue in the sump plug.

Attaching the engine mounts 

Plugging the speedo take offs on the gearbox.

Attaching the gearbox mount.

I also ran a cable along the harness to use for the oil temp. I will mount a switch on the dash and use it to select the between the oil and water temp sensors and display either on the temp gauge.