Three cylinders in my Caterham......

This little piece of the engine is a fuel injector and I need 4 working versions of these for the engine to run cleanly. This one is broken so I only have 3 working cylinders!
Amazingly all of the cooling system pipes and electrical connections were fine and the car started (after a bit of coaxing), but then we couln't get it to idle and realised it was only on 3 cylinders. Went through normal troubleshooting by swapping plugs and plug leads but then saw that the top of the piston on the suspect pot was still nice and shiny aluminium colour which meant it wasn't getting any fuel. Fortunately my able assistant (my nephew) knew a bit about injection systems (I am an old school carburettor guy!) and decided that we could take the system apart and look at the injectors. Bingo! We moved the injector to another cylinder and that went down. We had our culprit! A new one is in the post from Caterham! Good guys!

http://www.youtube.com/watch?v=u3KWM7t3UfM - the not so sweet sound, but loud!

Anyway that gave me a chance to finish off the rear suspension.....

All nice and shiny - for now!
Next stage is getting the engine properly fettled - tidying up wiring looms, pipes etc. and getting the roll bar fitted so I can bolt in the coil srping dampers (just tempoarily fitted currently).

Rear suspension taking shape!

I now understand how it all hangs together! The Watts Linkage (the two bars connected to the chassis in the top picture) also connects to the DeDion tube via the bell crank connection. This ensures the tube only moves in the vertical plane and not an arc (a single radius arm option), meaning that the wheel stays in better contact with the road.

Still need to install the disc and caliper but starting to look better all the time.

Next stage is obviously to get this finished but the most important bit will come up this weekend when I fill the car with all the required fluids, connect up the battery and try a start.

The diff is in - after a struggle!

 It took us about 4 hours to get the differential located in the chassis whereas Caterham say it should take 45 minutes! Probably next time (there won't be a next time!) will be quicker. The problem was you could get either the top bolts in or the bottom bolts in but not at the same time because the chassis holes were not in sympathy with the differential holes.
In the picture above you will see the metal we had to grind off the top bolt (top middle of picture) to make a point so that we could drift it through the width of the diff (bottom picture).

Anyway this now opens the door for the next stage which is getting all of the rear suspension on.

Cooling system complete!

 The radiator was the easiest bit!

 The lower of the two bottles in the picture is the oil breather bottle and it was missing when I started to install the cooling system stuff. Unfortunately the bracket had to be riveted on so I couldn't do the pipe work around the front until this was installed. As you can see it is now complete.

 The pipe work is now quite tidy after I took it all apart so that I could route it correctly!

It even has a heater!

The beast has a heart!

The engine is in! No problems really and all went very smoothly with the aid of an engine crane and a few bodies! Just a bit of lining up to do in the transmission tunnel to ensure the casing was central on the support.

All the electrical connections from the engine loom to the car loom were matched so you can't get them wrong. Now that the exhaust is on as well it is starting to look like a car! 

Its nearly engine time!!

The missing bits arrived so now the front suspension is complete. It is starting to look more like a car now (especially with one of the wheels on!).
Just need to mask up the engine bay so the engine/gearbox install doesn't mark the chassis too much and then it is engine hoist time at the weekend - if I can gather enough helpers. Volunteers??
Iain

Holiday time nearly over but not got as much done as I had hoped

Unfortunately Caterham have been closed down for this whole holiday period which meant I couln't get the rack brackets. I have also found (or not found!) that I don't have the left-hand cycle stay and as this has to be fitted onto the stub axle before the top ball joint is located, so this side of the suspension is not completed yet.
The break did give me time to do an inventory check so I have identified a number of items also missing, but will get all of these ordered this week ready for the weekend.
As to the right-hand suspension build I had no real problems as the manual is pretty good but I think the brake pipe is not located correctly in the inside of the chassis as the lock nut is taking too much thread.
At least I managed to get the engine and gearbox mated up and this now ready to go into the chassis when the front suspension is completed.