Newbie : Caterham Academy rebuild

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Fabnorman
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Newbie : Caterham Academy rebuild

Hi All,

First post on here so I'm hoping you'll play nice Smile

There doesn't seem to be a "Projects" section on here so I think I'm starting this in the correct section

In October last year, i bought what i think is a 2004 Caterham Academy car, it was originally used for the Caterham Experience, then passed to a company who used it as a development vehicle for motorsport parts/electronics, once they'd finished with it the car was stripped & stored in a barn until i had a chance conversation during which i mentioned that it was probably about time i tried a Caterham, one thing led to another & the car was dropped off a few days later as a rolling chassis, a 1.8 K Series engine, 6 speed Caterham gearbox & numerous box's of parts :

 

7_Malc
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Nice project!

If the Academy car was road registered, you may be able to track down a previous owner / driver on here.

Good luck with the rebuild.  

1800 K-series, Roadsport 140

https://www.youtube.com/channel/UCLyMVPqGXnNasgXYVeZYhkQ/

Golf Juliet Tango
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Welcome.

Enjoy the work and just ask questions when you need to.

I'll post a link to downloadable build manuals, I just need to look up the link.   - One of these should help, it you need it: http://www.caterham.dk/Assembly_Guides/

Stephen

Democratic dissent is not disloyalty, it is a positive civic duty

K7 VCT
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Welcome looks like an interesting project you have on your hands

Orange is my new black

Ballistic orange 310s
Toughie
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Welcome, Norman, and good luck with th rebuild.

There's always lots of support here.

Alan

Commercial Lead

Fabnorman
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Thanks for the comments guy's

The car is pretty much finished now but I figured I'd start this thread from the beginning

This forum has been completely invaluable as a source of detailed information, suppliers & tips/tricks, I doubt I'd have ever managed to finish it without L7C, particularly when it came to trying to sort the wiring, get everything working & get the motor running (special thanks to Andrew Revill)

If this is the correct place for this then I'll continue posting 

DougBaker
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Having rebuilt the car you can now look forward to the really fun bit of wearing it out again Smile

1.6K Roadsport SV

Fabnorman
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Once i started disassembly of the car it became apparent there were a few "issues" so i made some rotisserie brackets so i could roll the shell over for ease of access

Issues included :

Rear wheelarch fixings were a mess, the original rivnuts had pulled through & new holes/fixings had been done numerous times & then somebody had riveted aluminium sheet onto the outside with even more fixings 

The original handbrake brackets had been removed to fit a different type of gearbox & the handbrake was lashed in on a DIY bracket

The aluminium tunnel sides had chunks removed presumably to facilitate fitting the different gearbox

The aluminium under floor channels for the seat mount bolts were broken/bent

Some pics of the stripped shell :

700newtons
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Welcome to the club and enjoy the car Smile

Simon

 

Simon Houghton
Club Membership Secretary

Fabnorman
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With the bare chassis on the rotisserie i could set about the repairs 

The rear wheelarch fixings were the biggest problem, the sides of the panels were a bit of a mess so i removed the internal panels from behind the seats so i could get at the inside, then made some 3mm aluminium plates with M5 stainless fixings in & used a 3M structural 2 part adhesive to bond the plates on the inside, the adhesive not only bonded the plates in but coincidentally filled all the previous holes as well & once painted you'd never know 

Phil at Arch Motors sold me some new handbrake brackets & very kindly sent me some pictures with dimensions on so i could weld them into the correct position

I made some aluminium repair panels for the tunnel & some new 2mm stainless seat channels & riveted them on

 

Fabnorman
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After all that i had it painted, refurbished or replaced all the bushes, bearings, brake discs/pads, new seats, new carpets, fitted a heater, made all new water pipes to include more bleeds, modified the fan mounts on the new radiator to fit a 10" fan, fitted a Cartek battery isolator system etc, etc :