Caterham Assembly
Caterham Assembly
Caterham Assembly
8mm
ASSEMBLY GUIDE
B E T A E D I T I O N 1 . 0
DISCLAIMER
ASSEMBLY GUIDE
B E T A E D I T I O N 1 . 0
21 July 2016
i
ASSEMBLY GUIDE EDITION 1_BETA
HINTS & TIPS
When using a torque wrench, listen/ A ‘nyloc’ nut is one with a nylon insert that gets cut by the bolt
feel the click and then stop. It does thread, making it resistant to unwinding itself. This means that
not need to be any tighter and you they should not be repeatedly re-used.
might actually weaken the fixing by Chris B
‘over-torquing’ it. Always wind your
torque wrench setting back to free
when you’ve finished with it. When using a spanner, always use the ring
John K 1Nm of torque end wherever possible. The open end is
equals 0.736lbft. really only for those times that access is too
Mick F limited for a ring spanner or socket.
Mick A
4
ASSEMBLY GUIDE EDITION 1_BETA
HINTS & TIPS
You can tell if you have ‘wide track suspension’ car by looking Generally, metric
at the front dampers. Wide track has a 25mm long hexagonal Nyloc nuts have a
spacer between the top spring retainer and the mounting bush. blue nylon insert and
Matt T imperial ones a white
nylon insert.
Grant P
Thread lock is
used to stop
something
coming undone, Left and right are
A bolt size is described by its diameter
but it only as viewed from the
(eg M10=10mm) by the length not including
needs a little driver’s seat.
the head (eg 65mm).
drop on the Harrison P
James A
thread to be
effective.
Jamie A Teabag, boiling
water, then the
milk, in that order.
Simon L
1
ASSEMBLY GUIDE EDITION 1_BETA
KEY
S Y M B O L S
S Pack / R Pack
specific instructions
S3
S3 / S5 chassis specific instructions
S5
F I X I N G S
A
SERIAL
44
Pack
NUMBER
A
SERIAL
44 PACK NUMBER
Pack
NUMBER
FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options
BASIC PART
ITEM QTY USED ON ILLUSTRATION BASIC PART
DESCRIPTION NUMBER ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER
Anti-roll bar
x4 (Indicates number of each fixing required)
Bolt M8 x 40
5 AE BM8X40 4
Grade 10.9 mounting brackets Bolt M10 x 60 Upper wishbone
4 AD 2 BM10X60
Grade 10.9 front
Temporary use to
Plain Nut M14
6 AF x 1.5 thread
NMPH14 1 help lock upper
wishbone ball joint
Bolt M8 x 40 Anti-roll bar
5 AE BM8X40 4
Grade 10.9 mounting brackets
Lower wishbone
7 AG Nyloc Nut M12 NMYF12 2
rear
Temporary use to
Plain Nut M14
8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone
6 AF x 1.5 thread
NMPH14 1 help lock upper
wishbone ball joint
Plain Washer
9 AJ M12 WPCM12 18 Lower wishbone Lower wishbone
Chamfered 7 AG Nyloc Nut M12 NMYF12 2
rear
Plain Washer
Anti-roll bar
10 AK 4
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2
Plain Washer
9 AJ M12 WPCM12 18 Lower wishbone
Chamfered
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Heavy duty mounting brackets
2
ASSEMBLY GUIDE EDITION
Plain Washer 1_BETA
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe
Heavy duty
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2
KEY
T O O L S
LO
Allen key Pop rivet gun Socket wrench Thread lock
CT
Grease
IT
E
Socket wrench
+ Assistance Hammer Power adhesive
(allen)
Torque wrench
Pozidrive
Axle stand Heat gun Spirit level Trolley jack
screwdriver
Pozidrive
Combination
Junior hacksaw screwdriver Spray lube WD40
spanner
(stubby)
Copper slip S
Latex gloves UAL
Reading manual Stanley knife Tool
VE
MAN
tex
GLO
La
Flat dzuz
Marker pen Silicon Tap wrench Tool
screwdriver
Flat head
Muscle Silicon gun Tape measure Tool
screwdriver
3
ASSEMBLY GUIDE EDITION 1_BETA
LETS GET READY
P A R T S T O O L S
x3
F I X I N G S T I P S
When deciding how high your axle stands should be (the higher
the better for working on), don’t forget that a complete car will
need to come down off them, so make sure your trolley jack can
reach and lift the height you set them too!
Mick F
Some tape or foam on the top of the axle
stands will stop them scratching the chassis.
Matt T
4
ASSEMBLY GUIDE EDITION 1_BETA
LETS GET READY
5
ASSEMBLY GUIDE EDITION 1_BETA
START WITH THE SUSPENSION WISHBONES
P A R T S T O O L S
1 Lower wishbone
17mm
19mm
2 Upper wishbone
17mm
3 Wishbone bush sleeve
19mm
F I X I N G S T I P S
A A
SERIAL
44 SERIAL
44
Pack Pack For now, only tighten the nuts/bolts lightly and then torque them
NUMBER NUMBER
FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC) up when the car is finished and on the ground. This sets the bushes
ITEM
BASIC
This pack may include extra fasteners to cover different options
PART
QTY USED ON ILLUSTRATION ITEM
BASIC
This pack may include extra fasteners to cover different options
PART
QTY USED ON ILLUSTRATION
correctly and ensures the best handling.
DESCRIPTION NUMBER DESCRIPTION NUMBER
Harrison P
1 AA
Bolt M12 x 100
Grade 10.9
BM12X100 2
Lower wishbone
rear x2 12 AM
Spring Washer
M12
WSHM12 2
Lower wishbone
front x2
Anti-roll bar
2 AB
Bolt M12 x 65
Grade 10.9
BM12X65 2
Lower wishbone
front x2 13 AN
Spring Washer
M8
WSHM8 6
mounting brackets &
upper damper
mount
3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear x2 14 AP
Washer ⅜"
Shake-proof
WSS3/8 2 Brake pipe
4 AD
Bolt M10 x 60
Grade 10.9
BM10X60 2
Upper wishbone
front x2 15 AR Nyloc Nut ½"
Half height
NFYH1/2 2 Wing stay
Drawings are for illustrative purposes only and are not to scale. Page 2 of 2
Temporary use to
Plain Nut M14
6 AF x 1.5 thread
NMPH14 1 help lock upper
wishbone ball joint
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Heavy duty mounting brackets
Plain Washer
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe
Heavy duty
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2
6
ASSEMBLY GUIDE EDITION 1_BETA
START WITH THE SUSPENSION WISHBONES
35
AD
35 35
AC
35
mm mm
34Nm mm mm
34Nm
AH AH
AA
35
mm
AJ
35
mm
81Nm
AG
x2
AB
35
mm
AJ
35
mm
81Nm
AM
7
ASSEMBLY GUIDE EDITION 1_BETA
NOW FOR THE STEERING RACK
P A R T S T O O L S
1 Steering rack
10mm
13mm
2 Rack clamps
F I X I N G S T I P S
B
SERIAL
55
Pack
NUMBER
PACK NUMBER
30S003B
Finding the right IVA cover isn’t obvious
STEERING DeDION CARS (METRIC) because it is effectively a long cap. To use it,
ITEM
BASIC
This pack may include extra fasteners to cover different options
PART
QTY USED ON ILLUSTRATION
you cut the closed end off.
DESCRIPTION NUMBER
Jamie A
x4
Caphead Bolt
1 BA M6 x 70 BMCH6X70 4 Rack clamps
DIN 912
3 BC
Bolt M8 x 35
Grade 8.8
BM8X35 2
Column to rack
universal joint x2
Nyloc Nut ½"
4 BD Half height
NFYH1/2 1 Steering wheel boss
x4
Plain Washer
Rack clamps and
10 BK ¼" WPH1/4 6
Heavy duty column clamp
Spring Washer ¼
11 BL Heavy duty
WSH1/4 2 Column clamp
Drawings are for illustrative purposes only and are not to scale. Page 1 of 1
8
ASSEMBLY GUIDE EDITION 1_BETA
NOW FOR THE STEERING RACK
BC
35 35 20Nm
mm mm
BG
BA 5
35
mm
BH
35
mm
11Nm
BK 2 1
BE
9
ASSEMBLY GUIDE EDITION 1_BETA
AND THEN THE DAMPERS
P A R T S T O O L S
1 Spring / damper
6mm
F I X I N G S T I P S
A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER
PACK NUMBER
30F015B
PACK NUMBER
30F015B Put the top of the
FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC) damper on first.
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options
ITEM
BASIC PART
QTY USED ON ILLUSTRATION ITEM
BASIC PART
QTY USED ON ILLUSTRATION
Grant P
DESCRIPTION NUMBER DESCRIPTION NUMBER
Anti-roll bar
2 AB
Bolt M12 x 65
Grade 10.9
BM12X65 2
Lower wishbone
front
13 AN
Spring Washer
M8
WSHM8 6
mounting brackets &
upper damper
mount
x2 Mick F
Bolt M10 x 65 Upper wishbone Washer ⅜"
3 AC BM10X65 2 14 AP WSS3/8 2 Brake pipe
Grade 10.9 rear Shake-proof
Drawings are for illustrative purposes only and are not to scale. Page 2 of 2
Temporary use to
Plain Nut M14
6 AF x 1.5 thread
NMPH14 1 help lock upper
wishbone ball joint
Plain Washer
9 AJ M12 WPCM12 18 Lower wishbone
Chamfered
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Heavy duty mounting brackets
Plain Washer
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe
Heavy duty
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2
10
ASSEMBLY GUIDE EDITION 1_BETA
AND THEN THE DAMPERS
35
mm
35
AN
mm
20Nm 3
�
7
1
�
35 35 20Nm
mm mm
11
ASSEMBLY GUIDE EDITION 1_BETA
IT’S TIME FOR THE WINGSTAYS
P A R T S T O O L S
1 Wingstay
22mm
¾"
2 Front brake & upright assembly
F I X I N G S T I P S
A A
SERIAL
44 SERIAL
44
Pack Pack The drilled hole is for the side repeater earth that we’ll fit later. It’s easier
NUMBER NUMBER
FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC) to drill from the top and down through both sides of the tube, rather
ITEM
BASIC
This pack may include extra fasteners to cover different options
PART
QTY USED ON ILLUSTRATION ITEM
BASIC
This pack may include extra fasteners to cover different options
PART
QTY USED ON ILLUSTRATION
than through one side from the bottom (where the earth will be fixed).
DESCRIPTION NUMBER DESCRIPTION NUMBER
Tiago O
1 AA
Bolt M12 x 100
Grade 10.9
BM12X100 2
Lower wishbone
rear
12 AM
Spring Washer
M12
WSHM12 2
Lower wishbone
front Use the plain nut to
2 AB
Bolt M12 x 65
BM12X65 2
Lower wishbone
13 AN
Spring Washer
WSHM8 6
Anti-roll bar
mounting brackets & pull the top ball joint
front upper damper
mount
3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear
14 AP
Washer ⅜"
Shake-proof
WSS3/8 2 Brake pipe Some of the fixings required and shown on the nyloc, otherwise the
drawings, such as the ball joint nut, are already on thread will spin.
4 AD
Bolt M10 x 60
Grade 10.9
BM10X60 2
Upper wishbone
front
15 AR Nyloc Nut ½"
Half height
NFYH1/2 2 Wing stay
x2 the part and not in the fixing pack. Chris N
Anthony L
Front brake, upright
5 AE
Bolt M8 x 40
Grade 10.9
BM8X40 4
Anti-roll bar
mounting brackets
16 AS Nyloc Nut ½"
Full height
NFYF1/2 2 mounting (std track
ONLY) x2
Drawings are for illustrative purposes only and are not to scale. Page 2 of 2
6 AF
Plain Nut M14
x 1.5 thread
NMPH14 1
Temporary use to
help lock upper
wishbone ball joint
Put the ‘upright’ into the lower wishbone
Lower wishbone
joint then attach the steering before
7 AG 2
8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone all swinging around the hitting the side
9 AJ
Plain Washer
M12 WPCM12 18 Lower wishbone
of the chassis.
John S
Chamfered
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Heavy duty mounting brackets
Plain Washer
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe
Heavy duty
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2
12
ASSEMBLY GUIDE EDITION 1_BETA
IT’S TIME FOR THE WINGSTAYS
1 x1/8”
7
1 x1/8”
AR 2
x2
35 AS
35 54Nm
WIDE
mm mm
13
ASSEMBLY GUIDE EDITION 1_BETA
LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER
P A R T S T O O L S
1 Anti-roll bar
13mm
LO
CT
IT
E
5 Anti-roll bar dust cover
F I X I N G S T I P S
A A
SERIAL
44 SERIAL
44
Pack Pack Check that the colour of the mounting
NUMBER NUMBER
PACK NUMBER
30F015B
PACK NUMBER
30F015B Use four small cable ties
FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC)
rubbers matches the colour spot on the bar. to secure the dust cover.
BASIC
This pack may include extra fasteners to cover different options
PART BASIC
This pack may include extra fasteners to cover different options
PART
John K Mick F
ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER DESCRIPTION NUMBER
1 AA
Bolt M12 x 100
BM12X100 2
Lower wishbone
12 AM
Spring Washer
WSHM12 2
Lower wishbone Getting the assembled anti-roll bar
fully into both cups on the upper
Grade 10.9 rear M12 front
Anti-roll bar
2 AB
Bolt M12 x 65
Grade 10.9
BM12X65 2
Lower wishbone
front
13 AN
Spring Washer
M8
WSHM8 6
mounting brackets &
upper damper
mount
x4 Grease the balls and wishbone can be a bit of a fight.
3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear
14 AP
Washer ⅜"
Shake-proof
WSS3/8 2 Brake pipe cups generously. It’s made of springy stuff, so don’t
Matt T worry that you are bending it.
Bolt M10 x 60 Upper wishbone Nyloc Nut ½"
Jamie A
4 AD BM10X60 2 15 AR NFYH1/2 2 Wing stay
Grade 10.9 front Half height
Drawings are for illustrative purposes only and are not to scale. Page 2 of 2
Temporary use to
Plain Nut M14
6 AF x 1.5 thread
NMPH14 1 help lock upper
wishbone ball joint
Lower wishbone
7 AG Nyloc Nut M12 NMYF12 2
rear
Plain Washer
9 AJ M12 WPCM12 18 Lower wishbone
Chamfered
x4
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Heavy duty mounting brackets
Plain Washer
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe
Heavy duty
Drawings are for illustrative purposes only and are not to scale. Page 1 of 2
14
ASSEMBLY GUIDE EDITION 1_BETA
LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER
AE
35 35
AK 20Nm
mm mm
AN
4
15
ASSEMBLY GUIDE EDITION 1_BETA