Been Busy - Toxic Frog

[Gourlay83]

Caterham broke down on the way to Amp3 last year, due to clutch failure. Had a few other problems as well, suspension too soft/ride height too low and seized solid. So decided to take it off the road and sort it out for next years events (now this year )

Removed all the suspension, looked like this.




Chassis was untidy and corroded, believe due to fuel leak.


Cleaned up Chassis and re sprayed






All suspension components re coated, with new bushes and new shocks.






Carbon Fibre re coated.


Now to the clutch

Release bearing melted

Clutch Fork Cracked and bent


The clutch itself was so stiff (and worn), so have a new one ready to go in. Flywheel had also took a fair bit of abuse so it's with Stu to skim (hopefully be ok).

Gearbox has play in mainshaft and whines, so rebuilding that next week.

[111Robin]

Looking good Alan. If you need someone to polish it let me know

[Mikie711]

seen it in the flesh and I can attest to Alan's usual high standard of workmanship. Looks

[campbell]

You have T-minus 53 days and counting (approx) to ready that Wee Snot for the Road to the Isles Campaganza. No slacking now, young man

Mightily impressed Alan. Good luck with finishing touches.

Campbell

[Gourlay83]

seen it in the flesh and I can attest to Alan's usual high standard of workmanship. Looks

Thanks for pressing in the bushes Mike, lets me concentrate on putting the thing back together.

[Gourlay83]

Looking good Alan. If you need someone to polish it let me know

Cheers Robin (the guy I practically sit beside at work, but didn't realise you were the Robin from SE ).

[mckeann]

that looks amazing. Remind me to buy it once your finished with it. Oh, when are you doing the honda conversion??

[Peter]

Looks really good Alan, must be costing you a fortune in Jen gifts!

[Gourlay83]

that looks amazing. Remind me to buy it once your finished with it. Oh, when are you doing the honda conversion??

Nope, no honda Neil. Best engine for that car is the VHPD, light and plenty power. It now has a set of jenveys, correct cam timing and an Emerald. So nice and light throttle and pulls all the way through the rev range.

Still think it's a badly designed engine, crank too light/pistons not strong enough etc and it will blow up any minute now (even though it's not in the car ). As long as the con rods stay in the block, i'll like it !

Alan

[mckeann]

i'll need another shot now you've fixed the throttle bodies. THATS totally why i spun it

[mikeyb13]

seen it in the flesh and I can attest to Alan's usual high standard of workmanship. Looks

No arguments from me on that one. The elise scared the begeezes out of me round Spa

You dont bloody do things by halves mate. Looking forward to seeing it take shape

[David]

Very impressive Alan And here's me thinking you'd be at the SIDC last week! I didn't realise you where planning on a 'nuts and bolts' rebuild. Are those new Bilsteins, or did you send them back for reconditioning? I'll have to speak to you about the gearboxes sometime as mine will be on the overhaul list next year.

Looking forward to seeing the finished result soon

David

[Gourlay83]

Very impressive Alan And here's me thinking you'd be at the SIDC last week! I didn't realise you where planning on a 'nuts and bolts' rebuild. Are those new Bilsteins, or did you send them back for reconditioning? I'll have to speak to you about the gearboxes sometime as mine will be on the overhaul list next year.

Looking forward to seeing the finished result soon

David

I didn't plan the re build either. I had to raise the car as it was bottoming out and cracking sump pans, when i went to adjust the shocks/suspension everything was seized and well.... just a mess so had to re build it. Then I couldn't bolt new suspension on to a chassis in that condition, before i knew it I was rebuilding the entire car.

I've had to leave some items due to costs, Differential hasn't been touched (but now has oil ) and the engine is as before.

The shocks/springs were really bad, compared them to the new and there was about a 2" difference in height. It handled well before so can't wait to try them.

The gearbox is quite tricky, i've built plenty of gearboxs in my time but didn't like this one. It's basicaly a type 9, which needs the gears stripped from the shaft to gain access to the bearings. I would probably send away for a rebuild, i've heard places doing it for £300-£400.

[alicrozier]

[Andy G]

Sound move - you should have seen the state of the underside of the R400 and it was a 2008 car. They can corrode quite easily.