Build manual

[BrettJ]

I'm considering build my first Caterham, to ascertain if I this is something I can take on, I request the build manual from Caterham and this is what they sent: https://cms.caterhamcars.com/wp-content/uploads/2018/08/A4_Assembly_Guide_Edition_1.1_Spreads.pdf it seem a bit light only being 90 pages. Could someone please confirm if this is the complete build manual and if not could someone please share the complete manual?

[Jonathan Kay]

Please send me a Private Message with your email address.

Jonathan

[John Vine]

If you're planning to build a 420R (as your moniker implies), the build manual in CC's link (the IKEA-style one) is really only suitable for the Sigma models.  Regrettably, it's woefully short on Duratec info such as plumbing, as other current 420 builders (such as CtrMint) will attest. 

Your best bet would be to refer to the earlier text version as well.  No doubt JK will be offering to send it to you (master_-_caterham_cars_-_assembly_guide_-_february_2015c.pdf).  At 10MB and 220 pages, it's a full-bloodied guide and, IMHO, superior in most areas.

JV

[CtrMint]

Hi 420R as JV has mentioned, I've been attempting my first build, a 420R, and have to say the supplied and available Caterham documentation is terrible.

My kit was supplied with the Ikea style manual, which as pointed out by JV isn't even relevant for a 420, not that I was aware when I started, Caterham didn't make any attempt to mention there was an older manual I could source online which is more appropriate.  After much confusion Caterham told me to use the new manual for chassis only items.  The older manual does fill in some of the gaps but it is still incomplete due to some of the revised practices now used by Caterham.  As an example they fit the washer bottle in the boot stuff like that.

I've been through a lot of pain during my build and still am, and I would conclude the manuals are garbage, and the real source of guidance is here, the support from the members in Blatchat which is amazing!  You'll always get a response to any question at any level, so I wouldn't worry too much about the manual.  When I started out I was reluctant to ask too many basic questions for fear of the usual negative internet forum responses, I've learned that's not present here and the support is truly brilliant, infact they've given me a tremendous amount of morale support to keeping trying too !

Some  might consider my statement about the manuals been garbage a bit harsh.  Its just I've found so many omissions or misinformation in them, you just end up in a position where you take the manual with a pinch of salt, and that's not a good thing.

 

[John Vine]

Some  might consider my statement about the manuals been garbage a bit harsh.  Its just I've found so many omissions or misinformation in them, you just end up in a position where you take the manual with a pinch of salt, and that's not a good thing.

Harsh, maybe, but understandable given the grief you've encountered! 

As I see it, CC's problems regarding build manuals (aka Assembly Guides) can be summed up like this:

The IKEA-style one:  I think this is a good attempt at producing a more visual guide.  Of course, assembling a 7 is more complicated than a flat-pack desk, but I think the principle still holds. Certainly, the diagrams show clearly the orientation of parts and the relationship between them.  The main snag at the moment is that the info provided is incomplete as it doesn't apply to all models.  Not including Duratec-specific stuff is unforgivable in my view, especially as those models are the more expensive ones.  I would like to think that the current manual is simply work-in-progress, with someone beavering away to complete it!

The older-style text one:  Where this is lacking in visual appeal it makes up for in textual detail (which, personally, I prefer).  Of course, it's now old iron and CC no longer support it or offer it to builders.  The big problem was how to cover accurately all the various models in a single publication.  IME, it's a daunting challenge to do this well while maintaining a readable and flowing document.    

A problem for both is how to keep abreast of various engineering changes.  CC produce for their own internal use a set of Workshop Notices, which set out details of minor design and production changes. Some of these make their way into the 7 community.  It would a big bonus if the relevant ones could be appended to the Guide right from the start.

JV

[Grubbster]

CC must get asked many build related questions all the time and I believe they generally respond quite well with notices, photos etc. Many years ago I suggested they make these docs available to registered users online as a way of helping people trying to build their cars, but they didn't take up the idea. The usefulness (or otherwise) of the assembly guides has been legendary for as long as I can remember so I can't understand the reluctance to host some photos and pdfs, can't be hard surely?

[ChrisC]

Hi 420R 

I think you shouldn't worry about the manual, given the complexity of what they are trying to archive in a single document (either style) with ever changing specifications its actually not bad.  It gets you close, and as already mentioned there is plenty of support, Caterham themselves, blogs and blatchat all are fantastic sources of information.

The real question you need to ask yourself is how practical are you?   I don't think you need to be a mechanic, or have years of experience working on cars to build a Caterham, but you must at least know your way around basic hand tools, and be happy to use them on cars, or find someone who does, and is prepared to help.   Better still get in touch with the local club meet,  there is always someone, like me, that loves working on Caterhams, and has all the tools/experience you could possibly need, and is willing to help for little more than tea and biscuits (when needed).   Given the level of support available your confidence to complete the build wont be limited to the quality of the manual. 

Chris.

[BrettJ]

Hi Everyone,

Thank you all for the your responses. I’ve had a brief read of the old the manual and there isn’t anything which stands out. I don’t understand how CC can think that the newer version is a suitable replacement, but I’m not going to dwell on that. However I’m sure they would have a lot more queries and unhappy customers without this group.

My only other real concern is the build quality, I’ve heard that CC are painting the car in house and paint peeling due to poor preparation, can anyone confirm if they’ve step up their game? Also after reading Mark’s (CtrMint) blog and the issues he has had, is this just bad luck or are they all of a poor quality?

Brett

[John Vine]

It's over 10 years since I built my R400D, so I can't comment on recent build quality.  But I have to say the paint quality on mine is first class.

There's a current example of flaking paint on a new car here, and we're all watching to see what CC do about it.

Re Mark's (CtrMint's) experience, I would hazard a guess that it's an outlier in quality terms, but I stand to be corrected by those with more recent experience.  It seems to me he's been unusually unlucky. 

JV

[Tazio]

You do have to have the right temperament to build too, when things go wrong, and they will, walk away, don't try and persevere, that leads to frustration, and usually errors. Get to know your local club members, some may have been through this journey too and be happy to help. If in doubt....ask the dumb questions, usually you'll find they are not so dumb.

[CtrMint]

Hi 420R, 

The paint finish on my car which I guess has been painted in-house is first class, certainly in terms of the body panels. I asked Caterham to paint the car the same colour as my Lotus Exige and they've certainly done a brilliant job of reproducing an exact match so I can't complain.  The car has yet to hit the road so I'm not sure if I'll suffer any peeling from the chassis as shown by others.  

[ChrisC]

I assume this will be your first Caterham, because all Caterhams I have owned has always needed regular trips to the paint shop for paint repairs.  Paint is a consumable item on a seven, even with paint protection.  If the stone chips don’t get you the star cracks do.  My rear wings will be painted this year (my car was registered in March 2017) after a couple of star cracks are spoiling the look, the interesting thing is TSK (who painted my car originally) charges less to refresh a rear wheel arch than it costs to have paint protection applied, so why bother.   You just can’t get hung up on paint or your never use the car.  

As for quality I don’t think anything has changed recently, it’s a kit car and components can fail, but is that Caterham’s fault.  My car has had a number of component failures, all resolved under warranty.   All I see is quality improvements like the reduction of remanufactured parts, replacing then with new alternatives in recent years.