Right, I've fitted everything at the front except the steering rack. You should know that it's not arriving today after all. It was only sent today and assuming the courier Caterham use deliver on a Saturday, I'll now get it tomorrow.
I've now attached the braided hoses to the calipers which was tricky as the hoses aren't too flexible. Additionally, the Assembly guide describes a small and a large copper washer to go on the banjo bolt but all the washers are now the same size. I still need to find out if the anti-rattle washers supplied with the banjo bolts are needed...
Roll bar went on OK but bear in mind that the balls shouldn't be pushed all the way into the sockets as the bush mounts might go past the chassis rail. This picture might help...
Or it might not...
I'm now moving on to some chassis prep before the engine goes in. I've drilled the holes for the washer bottle bracket but as the Assembly Guide doesn't specify which rivet is needed, Caterham Midlands have suggested 'any that's long enough that will also accept a small washer on the inside'. There is a long rivet in the Fastener pack with all the others so I'll take three of those.
The horns are relatively easy once you've got the 13mm nut loosened (which I did by holding the horn on the boss that the nut is on in some grips). Up next was the washer nozzle which is horrible. In order to hold the plastic nut so that the nozzle can screw in, I taped it onto a 10mm socket which was on a 6" extension. Tighten it with a 13mm socket on the extension but only by hand - even then I managed to split the nut (which resulted in the first swear word of the day). A quick trip to Allen's Motor Services and a replacement was sourced (along with a spare nozzle). For the record, it's an AUTOBAR WASHER JET - DOUBLE - 841. It's exactly the same.
I'm off to tackle some riveting - I really hope that the holes are in the right place.
And there's an additional item turning up tomorrow: a fuel filler cover (which I think I've got already...).
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