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Aeroscreen doesn't fit.


martyn

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Today I received a Caterham interchangeable aeroscreen.  While trying to set it up, I realised that the fit isn't that good..

With the aeroscreen bolted at the sides, the centre base sticks up at a considerable angle..

aeroscreen.jpg.85bc88d0e2d00b56377663c9593e369e.jpg

I can press the screen into place; it takes a bit of force because the carbon is reasonably stiff.

aeroscreenpushed.jpg.a20ee89e7b4039b341d23e1749f0af20.jpg

However, doing this means that the base is at such an angle that the dot fasteners (when I fit them) won’t be square with each other. Because of this I am concerned that they won’t be able to hold in place over a bumpy road with the carbon pulling up on them.

Another concern is that the base piece is bonded onto the main piece.  Over time, will this joint be able to take the twisting load that would be put through it.

Are they all like this, and should I just get on with fitting it?  Or should I consider sending it back?

It’s a 2008 factory built car with nothing unusual about the scuttle (as far as I know).

Thanks.

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If you remove the knee trim panels which are screwed in place, you can adjust the height or angle of the captive nut brackets with washers. May need to enlarge a hole in sideskin to get the angle you need ?
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I would look at making the bolt holes in the aero elongated so that you can introduce some slack into it. It probably only needs a couple of mm's each side and you'll be able to position it as you want.

Just remember a mask and protective glasses while doing it. 

Nothing ever fits perfectly on a Caterham...

Simon

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If you remove the knee trim panels which are screwed in place, you can adjust the height or angle of the captive nut brackets with washers. May need to enlarge a hole in sideskin to get the angle you need ?

I'd prefer not to mess with the captive nut brackets too much as I need the windscreen to be easily interchangeable.  And actually the problem isn't the height of the hole but the fact that they seem to be too far back towards the rear of the car.  With the aeroscreen unbolted and held in place in the middle, the ends of it are nowhere near the holes.  In fact the ends are out where the bonnet meets the scuttle - That's how much adjustment or flexing/bending I'll need to get it to fit.

I would look at making the bolt holes in the aero elongated so that you can introduce some slack into it. It probably only needs a couple of mm's each side and you'll be able to position it as you want.

For me the holes will need to be fatter rather than longer as it is horizontal movement I need.

I think a combination of the following should work..

  • Mounting the aero as far back as possible.  Maybe even removing the scuttle edge trim to get it further back.  Placing the rear of the aero base over the edge trim also seems to work well as seen here.  This holds the base horizontal rather than pulling it down at an angle.
  • Moving the captive nut brackets forward 2mm.
  • Enlarging the holes on the aero.

Any other tips to get this to fit?

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My CC aero fitted fine on my imperial car (2005) but not on my metric (2009) I fitted the the aero in position with the poppers (where the tonneau fits) then drilled two holes in the aero to match up with the relevant holes in the scuttle. Good tight fit now though I do have two unused original holes! Hope this helps.

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Thanks John,  Its good to know that most people need to do some DIY before it will fit properly. The problem with mine is that none of the aeroscreen overlaps the hole - not even close.  In fact, the end of the aeroscreen is closer to the "Superlight" decal on the bonnet.  So it's going to be a case of bending it into place and securing the best I can.

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For what they charge for these, the quality is crap quite frankly! I sent two carbon aero's back, before I got one that I could work with. Even then it wasn't perfect, as the centre bit where you put the poppers is not quite central, and is noticeable as I have stripes up to the scuttle. By this time I'd got fed up with the hassle, and just decided to keep it, which to be honest I shouldn't have done!

If it's really that bad, I'd send it back.

Oz....

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I fitted mine last week and I thought the same as you however once I left it to sit for a bit in place, the poppers fitted just fine.

 

I think it had lost shape a little while being sat on top of the wardrobe for a year ;-)

 

I truly believed there was no way the poppers would go on but when I finally did try it properly they went straight on. As you say, trying to pop on then bolt in looked completely wrong.

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I sent two carbon aero's back, before I got one that I could work with

Ozzy, are you saying that each one you received was slightly different?  I'd assume that they all come out of the same mould.

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Damo, did you have the same problem with the base plate being up at an angle?  Is your screen carbon or composite?  I wouldn't have though carbon could lose its shape, but I could be wrong.

Did you find the poppers more secure than you expected once connected up?

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Yeah genuine caterham carbon, mine is SV.

i also have a rubber strip around the leading edge of my scuttle which I notice you don't.  Mine had to push down on this also.  Again it didn't look possible!

i found roughly 1cm of the curves which the poppers are fixed to hangs over the scuttle.

i did a whole day at brands last week without drama at all.  Mine was also at an angle

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Yes I do have the scuttle trim, but I took it off when playing around with this aeroscreen.  I have noticed that the fit is a bit better with the aeroscreen base (curvy bit) overlapping the trim.  That holds the base squarer onto the poppers.  Mounting the aeroscreen that far back also means I have less far to bend the legs to get the bolts through the holes.

Just waiting for the dot fastener tool to arrive tomorrow then I'll go for it.

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I have same as Damo (SV).  I loosely put the bolts in and then put the poppers on.  Takes a bit of force to get them to pop.  I then tighten the bolts.  I also have the scuttle trim which I have to pull forward slightly to allow the poppers to seat.

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I had the same issue with mine when I went to fit it a few weeks ago.   I ended up fitting the two side allen bolts and then drilling two new centre holes in the CF to suit its placement.  They were out by about 12mm before I drilled them.

When drilling the CF I masked the front and back and used very little pressure on the bit.

On a recent trip to Caterham Gatwick I had a look at the aeroscreens they have on their cars and they all seemed to have a small gap under the drivers side. 

HTH.

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