Here, there and everywhere

Just to complete the pictures of the front suspension...

You'll see the steering rack is now in - I can't finish the front until the engine's in.

As I need some help in getting the engine in, I figured I should start on the rear suspension. As the diff is now firmly in place, I put the brake pipes on the De-Dion tube and set about assembling the calipers {note that when you offer the rigid brake pipes against the De-Dion tube, you have to form them to the shape of the tube by pushing them GENTLY against the De-Dion. Additionally, the ends that will ultimately attach to the caliper will stick up in the air - these will require bending to suit}.

Sadly, the caliper assembly instructions are incomplete in the Assembly Guide. Therefore, I can't be sure of the torque to apply to hold the two halves of the caliper together. There is a good guide on the Caterham Motorsport Forum sent to a 2009 racer. Follow this link to find it.

As I can't get the rear spring/damper units fitted until after the roll-cage goes on, I set about putting the seats in - starting with the seat belts (or racing harnesses!). There isn't a torque value quoted for the shoulder straps so I've assumed them to be the same as the lap straps for the time being.

Anyway - there are a couple of things to look out for. There are two holes in the transmission tunnel where you have to mount the inner lap strap - make sure you use the forward one (it's the one with the riveted indented panel beside it). Hopefully this piccie will help - I got it wrong the first time (and I felt like an idiot!)...

Secondly, you need to drill two holes for the crotch straps for the 6-point harness through the floor. I checked several times to make sure the holes were in the right place BEFORE I started drilling. Additionally, I started with a small pilot hole from above before drilling the hole to the correct size from below.

Once I got the harnesses in, I tried fitting one of the seats - but I had to stop before fitting it altogether as I need to add the rubber piping on the inner panels (by the sill) but I can't do that until the roll cage is in.

The harnesses look good...

Just make sure the lap straps are fitted the right way round...

So I went back to the rear suspension. I got the radius arms fitted OK, and then the A-Frame. Only the upper radius arm bolt is torqued at the moment so still lots to do. Driveshafts next...

So I've been from the back to the middle and to the back again. I've got three potential options for continuing - the engine and gearbox, the roll-cage or the driveshafts. Not really sure which to do next...