Caterham self-assembly
Discussion
Looking at a new house at the moment which will have a large garage and therefore the potential to act as a Workshop for a new build.
However, I’ve never done anything like this, so want to understand what is required and how mechanically-minded you need to be to build a new Caterham?
I would be doing things slowly and carefully and learning new skills on the way - presumably I’d need to factor in a decent amount for equipment to help with the build, as well as the car itself?
Does anyone have any experience and can point me in the right direction - maybe a blog from someone who’s done this before?
Cheers
CL
However, I’ve never done anything like this, so want to understand what is required and how mechanically-minded you need to be to build a new Caterham?
I would be doing things slowly and carefully and learning new skills on the way - presumably I’d need to factor in a decent amount for equipment to help with the build, as well as the car itself?
Does anyone have any experience and can point me in the right direction - maybe a blog from someone who’s done this before?
Cheers
CL
Hi I finished building mine in June. Mechanical knowledge doesn’t have to be extensive and doing it slowly works. ( I started in October)
The kit is challenging because you are never quite sure if you have all the parts and some fitting tasks are less than clear I found forcing myself to be chilled worked
However overall it’s not difficult and very very satisfying I deliberately avoided having help from anyone with experience ( except via e mail etc) to see if I could do it myself
In terms of help joining the Lotus Seven owners club worked for me ( v helpful members) and questions to Caterham throughout the build worked.
Lots of blogs I just googled them
Tools are listed in the manual. Overall I used Halfords Professional tool kit and bought what I needed as I got to the build point when required. Specialist kit like the engine hoist I borrowed from Lotus Seven owners ( there is a list of people willing to lend).
So for what it’s worth I think you will enjoy it
The kit is challenging because you are never quite sure if you have all the parts and some fitting tasks are less than clear I found forcing myself to be chilled worked
However overall it’s not difficult and very very satisfying I deliberately avoided having help from anyone with experience ( except via e mail etc) to see if I could do it myself
In terms of help joining the Lotus Seven owners club worked for me ( v helpful members) and questions to Caterham throughout the build worked.
Lots of blogs I just googled them
Tools are listed in the manual. Overall I used Halfords Professional tool kit and bought what I needed as I got to the build point when required. Specialist kit like the engine hoist I borrowed from Lotus Seven owners ( there is a list of people willing to lend).
So for what it’s worth I think you will enjoy it
haddock said:
Hi I finished building mine in June. Mechanical knowledge doesn’t have to be extensive and doing it slowly works. ( I started in October)
The kit is challenging because you are never quite sure if you have all the parts and some fitting tasks are less than clear I found forcing myself to be chilled worked
However overall it’s not difficult and very very satisfying I deliberately avoided having help from anyone with experience ( except via e mail etc) to see if I could do it myself
In terms of help joining the Lotus Seven owners club worked for me ( v helpful members) and questions to Caterham throughout the build worked.
Lots of blogs I just googled them
Tools are listed in the manual. Overall I used Halfords Professional tool kit and bought what I needed as I got to the build point when required. Specialist kit like the engine hoist I borrowed from Lotus Seven owners ( there is a list of people willing to lend).
So for what it’s worth I think you will enjoy it
That’s a really helpful post, many thanks!The kit is challenging because you are never quite sure if you have all the parts and some fitting tasks are less than clear I found forcing myself to be chilled worked
However overall it’s not difficult and very very satisfying I deliberately avoided having help from anyone with experience ( except via e mail etc) to see if I could do it myself
In terms of help joining the Lotus Seven owners club worked for me ( v helpful members) and questions to Caterham throughout the build worked.
Lots of blogs I just googled them
Tools are listed in the manual. Overall I used Halfords Professional tool kit and bought what I needed as I got to the build point when required. Specialist kit like the engine hoist I borrowed from Lotus Seven owners ( there is a list of people willing to lend).
So for what it’s worth I think you will enjoy it
Hi,
A few comments from a newbie....
Provided you’re methodical and with good attention to detail, I think you’ll find the build a breeze. Yes, you’ll be frustrated at times (missing parts, confusing build manual), but in the end you’ll feel you’ve really achieved something. And if you get stuck, Caterham Cars have a very helpful guy dedicated to supporting kit builders.
I’ve built two sevens over the years: a K-series Roadsport and a Duratec R400. I found both to be an amazingly satisfying experience. The key is to take your time and not to be constrained by tight deadlines (such as the IVA test).
That Halfords toolkit is a good start (I have the same set). But you’ll need a few other tools as well, such as a pop riveter, torque wrenches (one up to 90Nm, the other up to 300Nm for the rear hub nuts), a good jack, axle stands, an engine crane, and possibly a crimping tool (for wayward connectors) and a multimeter (for electrical gremlins). If funds allow, you could even consider the comprehensive 7-friendly Draper toolkit that Caterham sell for kit-builders. If you don’t want to buy some of the specialist tools, you can very likely borrow them from Lotus 7 Club members (you’ll need to be a Club member to do this).
If you’re not already a member, do join the Lotus 7 Club. There’s a wealth of expertise and experience available, from the S1 right through to the bonkers 620.
Good luck with your new project!
A few comments from a newbie....
Provided you’re methodical and with good attention to detail, I think you’ll find the build a breeze. Yes, you’ll be frustrated at times (missing parts, confusing build manual), but in the end you’ll feel you’ve really achieved something. And if you get stuck, Caterham Cars have a very helpful guy dedicated to supporting kit builders.
I’ve built two sevens over the years: a K-series Roadsport and a Duratec R400. I found both to be an amazingly satisfying experience. The key is to take your time and not to be constrained by tight deadlines (such as the IVA test).
That Halfords toolkit is a good start (I have the same set). But you’ll need a few other tools as well, such as a pop riveter, torque wrenches (one up to 90Nm, the other up to 300Nm for the rear hub nuts), a good jack, axle stands, an engine crane, and possibly a crimping tool (for wayward connectors) and a multimeter (for electrical gremlins). If funds allow, you could even consider the comprehensive 7-friendly Draper toolkit that Caterham sell for kit-builders. If you don’t want to buy some of the specialist tools, you can very likely borrow them from Lotus 7 Club members (you’ll need to be a Club member to do this).
If you’re not already a member, do join the Lotus 7 Club. There’s a wealth of expertise and experience available, from the S1 right through to the bonkers 620.
Good luck with your new project!
Tenareze said:
Hi,
A few comments from a newbie....
Provided you’re methodical and with good attention to detail, I think you’ll find the build a breeze. Yes, you’ll be frustrated at times (missing parts, confusing build manual), but in the end you’ll feel you’ve really achieved something. And if you get stuck, Caterham Cars have a very helpful guy dedicated to supporting kit builders.
I’ve built two sevens over the years: a K-series Roadsport and a Duratec R400. I found both to be an amazingly satisfying experience. The key is to take your time and not to be constrained by tight deadlines (such as the IVA test).
That Halfords toolkit is a good start (I have the same set). But you’ll need a few other tools as well, such as a pop riveter, torque wrenches (one up to 90Nm, the other up to 300Nm for the rear hub nuts), a good jack, axle stands, an engine crane, and possibly a crimping tool (for wayward connectors) and a multimeter (for electrical gremlins). If funds allow, you could even consider the comprehensive 7-friendly Draper toolkit that Caterham sell for kit-builders. If you don’t want to buy some of the specialist tools, you can very likely borrow them from Lotus 7 Club members (you’ll need to be a Club member to do this).
If you’re not already a member, do join the Lotus 7 Club. There’s a wealth of expertise and experience available, from the S1 right through to the bonkers 620.
Good luck with your new project!
Again, thanks for you helpful comments. The project relies on a new house / garage first, so won't be starting imminently, but i thought it would be a good opportunity to start the research.A few comments from a newbie....
Provided you’re methodical and with good attention to detail, I think you’ll find the build a breeze. Yes, you’ll be frustrated at times (missing parts, confusing build manual), but in the end you’ll feel you’ve really achieved something. And if you get stuck, Caterham Cars have a very helpful guy dedicated to supporting kit builders.
I’ve built two sevens over the years: a K-series Roadsport and a Duratec R400. I found both to be an amazingly satisfying experience. The key is to take your time and not to be constrained by tight deadlines (such as the IVA test).
That Halfords toolkit is a good start (I have the same set). But you’ll need a few other tools as well, such as a pop riveter, torque wrenches (one up to 90Nm, the other up to 300Nm for the rear hub nuts), a good jack, axle stands, an engine crane, and possibly a crimping tool (for wayward connectors) and a multimeter (for electrical gremlins). If funds allow, you could even consider the comprehensive 7-friendly Draper toolkit that Caterham sell for kit-builders. If you don’t want to buy some of the specialist tools, you can very likely borrow them from Lotus 7 Club members (you’ll need to be a Club member to do this).
If you’re not already a member, do join the Lotus 7 Club. There’s a wealth of expertise and experience available, from the S1 right through to the bonkers 620.
Good luck with your new project!
In terms of build difficulty, are all the models broadly similar (just with different engines) or are some models designed for experts to build?!
It is pretty easy, but you do need to know how to spanner, use torque wrenches, how to not cross thread nuts and bolts, how to wriggle things in, when to fettle, when something is going to fit and when it's the wrong part. There are also some jobs that are better with two people. Engine and box in, diff in to name a couple. If you've never held a spanner before, you might be better with more help rather than less.
Bert
Bert
I built my R400 in 2015; no significant issues but I’m an engineer by profession with previous experience in automotive stuff.
The build manual at the time I would have rated about 6/10 though Derek, the build contact, was pretty good at clearing up minor issues and getting missing stuff sent out. I didn’t have too much missing (though one part was a drive shaft, how does that get missed?!) and I still have a few spares that were duplicated.
I built an R400 because it was the fastest kit available, as the 420 (same thing) is now I believe. Now that they’ve discontinued the 160 I think, they’re all much of a muchness.
Just now they seem to have major issues with the 420 kits having ‘upgraded’ the cooling system and not done it very well. There are a couple of threads on the L7C about that but it will hopefully be sorted by the time you buy.
Very wise to have help at some points but there’ll almost certainly be someone with experience near enough to help if needed.
The build manual at the time I would have rated about 6/10 though Derek, the build contact, was pretty good at clearing up minor issues and getting missing stuff sent out. I didn’t have too much missing (though one part was a drive shaft, how does that get missed?!) and I still have a few spares that were duplicated.
I built an R400 because it was the fastest kit available, as the 420 (same thing) is now I believe. Now that they’ve discontinued the 160 I think, they’re all much of a muchness.
Just now they seem to have major issues with the 420 kits having ‘upgraded’ the cooling system and not done it very well. There are a couple of threads on the L7C about that but it will hopefully be sorted by the time you buy.
Very wise to have help at some points but there’ll almost certainly be someone with experience near enough to help if needed.
Edited by anonymous-user on Saturday 22 December 16:46
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