progress update
 

its been a few months since i last posted up here about my progress so i thought i would give another update.

progress has been somewhat slow, due to work commitments meaning longer hours and weekends...and its been freezing so i nocked it on the head for a few months.

the last time i posted i was trying to sort out the clutch. i have it all installed but i am not happy with how heavy it is. so a job my my list is to remove the pedal box (Again!!!) and cut the clutch mounting plate out and re position the angle so that he master cylinder can sit on a hole closer to the pivot point without bending the pushrod! (clutch cylinder number 2 is needed!)

aside from that the car is mechanically complete and the engine runs pretty well. i think i have a few gremlins but nothing i cannot get around .

i have also pretty much fitted all the body work and taken it off again to finish building,

the rear lights have been fitted and wired up as well as the fronts. but the fronts are going to need a little bit of work, (either brackets making or stop locks on the steering rack to stop the tyres hitting the lights on full lock)

finally and the most time consuming part is i have been trying to make my own exhaust system. it has been a complete nightmare and not something i would recommend to any one without a proper pipebender and half decent tig welder! i have a rubbish tig welder and had to buy a load of pre made bends along with Two CATS and flanges... i had the whole system fully completed but got a head of my self and managed to absolutley cock one pipe up today so i have to remake a small section of it. unluckily for me it is a link piece and is a really really bad angle to try and link the pipes together! here are a few pics of the system :

http://i223.photobucket.com/albums/d...psg73htsxp.jpg

http://i223.photobucket.com/albums/d...psmraglwit.jpg

http://i223.photobucket.com/albums/d...psonbo41k5.jpg

i have tried to get both sides looking the same, there are some differences but to be honest i cant do any better with the tools i have!

http://i223.photobucket.com/albums/d...pszolfhcey.jpg

http://i223.photobucket.com/albums/d...ps5swqkb1z.jpg

its not great but it is the best i can do!

I'm not sure what the IVA man will say about the outboard cats... You may have to put a guard on them, as they're bound to get hot - hotter than the muffler boxes.

I couldn't find anything regarding it in the IVA manual, but this caterham builder put some perforated shields on his:

http://www.caterhamr500.co.uk/2014/0...x-exhaust.html

I'd hate for you to do all this hard work only for the man from Vosa to say no on the day.

My last kit car passed iva with an outboard cat. All gbsc zeros run outboard cats and none have had any issues, if presents its self as an issue then some exhaust wrap should suffice

Apologies I didnt mean for that post above to come across all matter of fact! Thanks for pointing it out!

No worries. I've never seen an outboard cat before... Hence my post. :)

That guy with the R500 looks to have swapped his cat after the test for something a bit more bling, and no cover on that! :D

It might be worth pondering on why Caterham supply and fit a cover?
I suspect the issue might be in General Construction which states...

"1. All aspects of the design and construction of the vehicle must be such that no Immediate danger is caused or likely to be caused to any person in the vehicle or to other road users."

This leaves it a bit open to interpretation by the IVA examiner, but I also have not heard of any failures.
For the cost of a fail, I'd knock up a couple of temporary covers that may fall off later.
Just Google 'Stainless cutlery drainer' and you'll see some suitable options :lol: Some even come with IVA friendly rolled edges!!

As with all parts of the IVA, prevention is better than cure.


...peter