Building a Caterham

One of the things I was reluctant to tackle- fitting the release hub to the steering wheel.

Traced a template of hub, measured center points and drew lines to find center of hub: Image Unavailable, Please Login Image Unavailable, Please Login

Used a nail to find the divot in the center of the back of the steering wheel.
Drew a center line on lower spoke to line up with template:
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Then, I used a center punch to mark hole location for lower spoke. Drilled progressively larger holes. Counter sunk the side facing driver. Attached hub with bolt/nut to steering wheel- center punched the next 2 holes, removed hub, then drill/ counter sink holes, then bolt up everything and put on car:

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I have marked up the hole to be cut, but I will have to wait for metal cutting implements.

Chose to move hole 2” forward (factory missed by about 1.5”) so that I can try to minimize gap asymmetry fore to aft. I will further reduce asymmetry by using a trim ring, applied a bit off center to hole I make.
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Cut the hole, pucker factor was high.

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Got it to sputter to life, running rough for the moment. Problem solving in process.

 

Days of trying to get it to run- checked everything imaginable.
Ultimately- sent ECU to Rocky Mountain Caterham (one more example of why Josh was essential). They uploaded newest tune (for which i adjusted throttle position sensor to a new setting)- miracle cure. Car running great in 2-3 minutes.

Not quite on the ground:
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On terra firma:
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Still need to adjust speed sensor and work on firming up brake pedal.

 

Great work, @sainthoo !

Matt

 

Enjoying your thread and interested in getting a caterham at some point in the near future. I communicated with Rocky Mountain Caterham about a year ago and have been meaning to meet with them and check out some of the cars in person.

What has your experience been with Caterham broadly speaking? Are the cars as much fun to drive and own as they look?!

 

I have not driven in anger yet- need to sort out a couple items, need to get registration/plates and make sure brakes are ready.

If you are considering it, I would highly, highly recommend Rocky Mountain Caterham- they are experts and good people (Josh sure is).

 

Another random item. I replaced all the bulbs with LED replacements:
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Nice work, cool car.

 

Dropped off my paperwork at DMV this AM…..

 

Are you on the road?

 

Still waiting for the DMV…. About to make up a fake plate “DMV- MIA”

 

I was curious, well hopefully before winter! Nice build.

 

Did you get your car on the road?

What are your driving impressions?

Very curious. I am meeting with the FL dealer to chat about my interest in building one.

 

Well, 1 final issue still not sorted- speedo. My car and the car that immediately preceded mine on the assembly line do not work (built after a lunch that included a few pints?)
They shipped a new speedo, I reset gap at speed sensor just to be sure…… and nada.

I have driven without speedo, a bit, not much (I got side tracked with life, so really only started trouble shooting a couple weeks ago). Car is pretty great to drive. I would not go for the bucket / racing seats- they look great but are painful after 30+ minutes (I’ve had GT3 RS, GT4 racing buckets, Senna seats, plus real race car seats, all more comfortable).

The build kit (parts in random bags with other parts totally unrelated) and manual (I was told to build out of order, some things are inaccurate) leave a bit to be desired.

When I finally get this sorted (now waiting for word from Caterham how to procede- still might be my error, but I doubt it) I just might pull the roll bar, put the full cage and wind deflector and keep it at my condo at VIR.

 

I put a deposit down on an Ultima RS kit. Visited shop in UK, might bail out- a bit tight, it would become a pure track car, and I already have those.

 

I've been watching an Ultima build series on YouTube as well. Very interesting cars. Just don't think I can swing the $$ for the Ultima.

Thanks for the guidance on the Caterham. I was thinking of going more S than R, so your seat advice is well taken.

Weird about the speedo issue. So is it down to the speed sensor or a cabling issue?

 

Speedo is good, must be a wiring problem (which was provided from factory- they do the dash)

 

Well, in the end, it was the speed sensor itself at the rear wheel. Replaced that about 1 month ago.

Then followed the instructions to calibrate the speedometer- trial and error with a GPS speedo app on my phone.

Finally finished my hand fabrication of an aluminum plate to cover the giant hole for the exhaust headers. After trial and much error with rattle cans, finally got a decent enough coat of black to look something akin to factory. With my son’s help, fitted exhaust back on, and applied the 2 exhaust clips- job done.

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(my youngest has been working hard in the gym)

 

Oops- meant to add this:
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