Another Super 7

A while back I set the rear bodywork aside not realizing it was on an uneven surface. Unfortunately it picked up a bit more than just a mild warp. I tried to bend it back into shape and it looked like it might fix it.
So I added four more hard mounting points with screw in fasteners on the frame and also keyed the bodywork to fit snugly onto the frame and it did help, but did not cure all the issues and it still needed to be trued up.

I flexed the body until I broke some of the joints and then fastened it to the frame.
Next I made two vertical relief cuts in the lower rear sides of the fenders. The one on the left side was drawn in…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02180_zps9ed79286.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02180_zps9ed79286.jpg.html)
…and the one on the right was shimmed out until the rest of the bodywork was trued up. Even the trunk lid fit properly again.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02179_zps5a57c41d.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02179_zps5a57c41d.jpg.html)
Additional brass and styrene bracing was bonded to the inside of the body to shore it up while it was still bolted to the frame. I also used laminating resin and three layers of fine fiberglass mat on the inside of the wheel wells for more rigidity and rebonded all the fractures I created by bending and flexing it.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02182_zps4d409316.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02182_zps4d409316.jpg.html)

A brass “leading edge” was added for strength between the fenders. You can see some of the piecework sheet styrene and CA construction where I have sanded through the primer.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02181_zps71d9afff.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02181_zps71d9afff.jpg.html)
Now it is strong enough to continue with the surface work without being bolted to the frame.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02178_zpsd6a966d6.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02178_zpsd6a966d6.jpg.html)

The basic exterior of the fuel tank is done and I added more parts to the frame for the mounts and made a pair of straps too. They will tighten up once the insulation is added. The screws will be replaced with bolts later.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02183_zpsd4ea5fd8.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02183_zpsd4ea5fd8.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02184_zps448bc00d.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02184_zps448bc00d.jpg.html)

More frame supports have been added…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02185_zps9041157d.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02185_zps9041157d.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02186_zps26f85d68.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02186_zps26f85d68.jpg.html)

This is the trunk inner liner. It is constructed of styrene and brass and fiberglassed for strength and appearance. The inside will be textured and finished later.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02188_zpsff26edb5.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02188_zpsff26edb5.jpg.html)
The round section at the forward edge is a separate piece that snaps on. It is the only way to install it into the frame.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02187_zpscf2b31fd.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02187_zpscf2b31fd.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02189_zps78e9321f.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02189_zps78e9321f.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02190_zpsf43c52e9.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02190_zpsf43c52e9.jpg.html)
The rear body section is also coming together after reworking the warp out of it… The primer is glossy; those are reflections not discoloration from sanding.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02191_zps32de1ae3.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02191_zps32de1ae3.jpg.html)
A side note, at this point it already weighs 11 ounces, that’s almost a ¾ pounder…

This awesome work inspires me to build another Lotus!

Differential and gearbox looks really similar to ford sierra diff and gbox

These are the rear shocks. Mostly brass with some aluminum for the piston shaft. I wound the springs from steel wire.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02192_zps1624f3ec.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02192_zps1624f3ec.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02193_zps8629be9e.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02193_zps8629be9e.jpg.html)

The trunk liner exterior looks like the real thing. Eager to see this masterpiece finished.

Since I am working on the trunk and the spare, I made this scissor jack. Just a dry run test, I’ll make another one with more details. This one is all brass with a steel jackscrew. I just wanted to see if it would work.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02195_zps6d1e8205.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02195_zps6d1e8205.jpg.html)
And yes, it does work.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02194_zps30df464d.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02194_zps30df464d.jpg.html)

Working scissor jack, now that is cool. Nice work Scalemaster!!!

I guess I already got tired of the wheel I made at the onset of this project. I also realized after working on the spare that I wanted more detail on the inside/backside of the rim. I made this wheel center to remedy both of those issues as well as making an overall thinner rim with the same bead dimensions. Still a little more clean-up required before a mold is made from it.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02234_zpsfd5320ee.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02234_zpsfd5320ee.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02236_zps05d0b174.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02236_zps05d0b174.jpg.html)
I also had to modify the rims I already cast to allow this larger diameter wheel center to fit, as well as to set it into the rim deeper for less overall width.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02232_zps42378f9c.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02232_zps42378f9c.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02233_zps77eb07da.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02233_zps77eb07da.jpg.html)

The jack on the right is the one I will use on the model. As you can see it is significantly smaller than the test jack, (70% of the size) on the left. It also is made of brass, but with a few machined aluminum parts too. Furthermore it has a pattern cut into the top pad that the larger one does not have.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02238_zps0b6225a3.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02238_zps0b6225a3.jpg.html)

It also works the same way as its big brother.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02239_zps490b3744.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02239_zps490b3744.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02240_zps2d5db836.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02240_zps2d5db836.jpg.html)
There is a fork on the handle that fits into the receiver. You can see the knurling I put on the handles too.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02242_zps81bb3667.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02242_zps81bb3667.jpg.html)

I think the new wheel design is the best so far, and these jacks are simply amazing!

You never cease to amaze me!

Thanks guys!

I need to add the seat mounting points to the frame, and needed seats to fit those to. These seats are items I cast from a master I made for my last Seven. I did some reworking around the seat belt guides in the headrest areas to the parts and I made a new mold for the guide inserts after I modified the pattern. Still more clean-up and finish work to do on them, but they are fine for measurements now…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02265_zps4fd3170c.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02265_zps4fd3170c.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02266_zps5dd175be.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02266_zps5dd175be.jpg.html)

Mark,
Your work is outstanding!

Trevor

Wonderful work, loving the detail & the jacks are tre-cool!

Thanks guys! It is a fun project...

The little jack is done. I weathered it a little, didn’t want it to look brand new…

http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02272_zps3d085786.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02272_zps3d085786.jpg.html)

http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02273_zps3e4880b9.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02273_zps3e4880b9.jpg.html)

I made the “tin work” for the transmission tunnel and rear bulkhead.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02294_zps51b545a6.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02294_zps51b545a6.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02295_zps964a433e.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02295_zps964a433e.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02296_zpsfdbbb356.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02296_zpsfdbbb356.jpg.html)

Finally got around to casting copies of the Weber carb I made. Each one is two parts, right now… Still lots of hardware to machine and details to add.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02302_zpsfe528786.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02302_zpsfe528786.jpg.html)

I also started casting the new rim centers.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02304_zps2b92178e.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02304_zps2b92178e.jpg.html)

Great building as always! The casted parts looks good =)

Once I got the rear body section mounting points established so I could put it on and take it off the frame and have it line up the same every time, I went back to setting up the rear suspension. I made the upper links that determine where the rear wheels would reside in relation to the wheel well openings. More brass…
I also made the outer CV joints and stubs to mount the rear rotors out of aluminum.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02530_zps4ee4f621.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02530_zps4ee4f621.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02529_zps876b82e9.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02529_zps876b82e9.jpg.html)
The CV boots will be soft and dyed black like the tires. The mold has already been made from this aluminum master I turned for them.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02531_zps7ed59a53.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02531_zps7ed59a53.jpg.html)

The fuel filler is made of brass, aluminum and some soft rubbery plastic that was a tube I had lying around from a paint brush bristle protector. Heating over a candle and bending it like sprue worked well.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02539_zpscecd07b3.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02539_zpscecd07b3.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02538_zpsc7b40e75.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02538_zpsc7b40e75.jpg.html)
The filler will be installed in the trunk.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02537_zps8cba7c55.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02537_zps8cba7c55.jpg.html)

I cast the CV boots out of a rubber-like elastomeric resin and made half-shafts out of brass. Here is one CV/axle assembly and a “loose boot”. The inboard CV joints are already installed on the pumpkin.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02541_zps4da86c44.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02541_zps4da86c44.jpg.html)
Here are both sides installed into the car. There is enough flexibility for the rear suspension to work. Top:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02542_zpsc817fcfd.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02542_zpsc817fcfd.jpg.html)
Bottom:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02543_zps1605ce90.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02543_zps1605ce90.jpg.html)

Since I was making CV boots, I decided to make the steering rack boots as well. I turned a master from aluminum and cast soft rubber-like accordion boots.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02545_zpsbe028c45.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02545_zpsbe028c45.jpg.html)

After I made a few steering rack bellows, I decided to make the rack, but I needed to make the cross member/mount for the rack first. All these assemblies are made of brass, (except the boots).
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02576_zps938cdea9.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02576_zps938cdea9.jpg.html)
Once I install it into the frame with the engine I can get measurements to determine where the steering shaft will go. This one has some “working boots” on it so I’m not worried if they marred during the building.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02574_zpsbe23efba.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02574_zpsbe23efba.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02575_zpsab0da31d.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02575_zpsab0da31d.jpg.html)

Man, hard to fathom that this has only gone 10 pages Mark. :confused: Truly OUTSTANDING work mate, an inspiration in all it's form. :worshippy

Thanks Greg!

The rack and pinion gears were cut from aluminum and the teeth section of the rack was cemented to brass guides. The rack teeth had to be pitched to match the input angle of the pinion. It does work.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02577_zpsdb09ef6d.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02577_zpsdb09ef6d.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02578_zps70833637.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02578_zps70833637.jpg.html)
It will be snug fit but the steering shaft should clear the alternator…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02579_zps91f04817.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02579_zps91f04817.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02580_zpsf99dbe37.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02580_zpsf99dbe37.jpg.html)

Amazing

I have been working on the master for the brake calipers. Still some refining to do, all brass.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02642_zps95856a84.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02642_zps95856a84.jpg.html)
Fits just right to the rotor…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02643_zps3a45f220.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02643_zps3a45f220.jpg.html)
And I’ll use these old calipers I machined from aluminum (at least ten years ago for a Camaro that ended up with drum brakes) for the mechanical parking / E-brakes.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02644_zps4f23aa03.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02644_zps4f23aa03.jpg.html)

The caliper castings are done. The brass half master is in the foreground, the completed master with mounting flange on the left, and a cast copy on the right.
The bolt detail that will be seen through the wheel will be added as individual machined hardware, I cast them into the part on the backside since they will be mostly hidden.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02767_zps3dee0550.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02767_zps3dee0550.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02766_zps7d5ad4d1.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02766_zps7d5ad4d1.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02765_zpsb16ec011.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02765_zpsb16ec011.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02764_zpsba9f97ec.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02764_zpsba9f97ec.jpg.html)

Once the main calipers were set up I was able to position the parking brake calipers. I had to add material to the DeDion tube assembly to make the mounting surfaces.
The calipers are machined from aluminum, leftover parts from a previous project that I decided to use drum brakes on after I made them. I still need to make the brake pads…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02768_zpsb4103af2.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02768_zpsb4103af2.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02769_zpsa5e4a05d.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02769_zpsa5e4a05d.jpg.html)

A side note: Today marks the one year anniversary of the start of this project.

You are truly a scale master sir! Incredibly detailed work, a museum masterpiece.

Rick

Thank you Rick, very kind of you to say.

Made the top of the sender for the fuel gauge… I’ll make and add the mounting hardware later.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02770_zps86086350.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02770_zps86086350.jpg.html)

While I am waiting for the acid to cut the brass control arm brackets I decided to make the lower control arms.
Since I only need two and I didn’t think the time spent making a jig would pay off, I just went for it.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02773_zpsd38a4b84.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02773_zpsd38a4b84.jpg.html)

The upper control arm and shock brackets are cut. I etched the areas the brackets will be soldered to the base as well as the bend lines in the brackets.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02775_zps76b4938e.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02775_zps76b4938e.jpg.html)
Here they are bent…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02777_zps7d42e6ed.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02777_zps7d42e6ed.jpg.html)
And all soldered together.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02778_zps450beaad.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02778_zps450beaad.jpg.html)
I also made the lower shock mounting pad/A-Arm reinforcement plates for the lower control arms.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02776_zps042d837d.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02776_zps042d837d.jpg.html)
And added the pivot/mounting points to the frame for them.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02779_zpsf3406b1f.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02779_zpsf3406b1f.jpg.html)

Upper control arms are roughed out and I’m working on the spindles now. I also finished the front bushing assemblies for the lower arms.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02794_zps67866584.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02794_zps67866584.jpg.html)

The spindles are fleshed out and close to being done, the left is on the left, the right is on the right…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02795_zps1be3d3bb.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02795_zps1be3d3bb.jpg.html)
I machined the “bearings” for the rotors, ironically exactly one year to the day of when I made the rotors. And I’m prepping the calipers which are the same basic units as the main rear calipers.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02796_zps576b6579.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02796_zps576b6579.jpg.html)
Inboard side of the left spindle assembly… The screws are just to tack it together as I build measure and adjust; hex head hardware will be fabricated and used on the final assemblies.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02797_zps4fb42dbf.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02797_zps4fb42dbf.jpg.html)
And mounted to the control arms…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02798_zps1d7dd0b6.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02798_zps1d7dd0b6.jpg.html)

For the first time it is up on all four wheels & tires. After only one year and 9 days of work… (But there are scores of other parts not shown here).
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02800_zps21bd28e9.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02800_zps21bd28e9.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02799_zpsede581aa.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02799_zpsede581aa.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02803_zps3d9deaf1.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02803_zps3d9deaf1.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02801_zps4aea6a43.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02801_zps4aea6a43.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02804_zpsf915f01e.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02804_zpsf915f01e.jpg.html)

Man this could pass as a 1:1

The (working) steering rack assembly is done, the last pieces being the tie rod parts. The tie rod ends are adjustable so it can be aligned once it is finally assembled.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02806_zps9a65ae69.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02806_zps9a65ae69.jpg.html)
The tie rod ends are just pinned into the spindles; the final assembly will have proper fittings there. (Those are red bread ties holding the A-arms together…)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02805_zps32e7f692.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02805_zps32e7f692.jpg.html)

After I had the wheels on the chassis I learned I needed more travel in the shocks to attain the proper ride height, which meant I needed to make longer springs. I used piano wire instead of soft beading wire this time. The beading wire is easy to work with, but has no memory and is too weak for this application. I went through about 12 feet of piano wire before I figured out how to get the windings even and the right diameter to fit over the shock. It snaps on both ends of the shock now and ties them together.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02820_zps0957f393.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02820_zps0957f393.jpg.html)
Then I went on to making the front shocks. This time I dealt with the spring before making the shock, it’s much easier to size the shock body to fit the spring than the other way around.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02818_zps80885d8a.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02818_zps80885d8a.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02819_zpsef458316.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02819_zpsef458316.jpg.html)

Fantastic work, a true Model Engineering masterpiece.

Time to make the nose… I started by building the areas that will mount the nose to the frame and hood out of sheet styrene and brass. Much of this part will be cut away and discarded later.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02824_zps41a9587b.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02824_zps41a9587b.jpg.html)
It is reinforced in part of the area that will be removed to make cutting it out easier. Final shaping of where the nose meets the hood will be done after the nose is built.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02823_zpsb92f65c8.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02823_zpsb92f65c8.jpg.html)
The main/front section is growing towards the mounting points; right now it is just sheet styrene and CA.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02822_zpsa02453e9.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02822_zpsa02453e9.jpg.html)

More great workmanship, wonderful!

The brass work is inspiring! :)

Thanks!
More plastic has been added and shaped… Now it has the final overall shape and dimensions.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02825_zps07012d23.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02825_zps07012d23.jpg.html)
The inner structure has also been beefed up for rigidity and to make it less prone to damage when I cut the insides out.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02826_zps2965b21d.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02826_zps2965b21d.jpg.html)

A couple coats of polyester primer (sanded in-between) and it’s time to remove inner structure.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02830_zpsa546ffcd.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02830_zpsa546ffcd.jpg.html)
Once I cut out the inner reinforcements I fiberglassed the insides for added strength and to replicate the inside of a fiberglass part.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02831_zpsb96f1104.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02831_zpsb96f1104.jpg.html)

The front fenders will be the cycle style. I started by making a circular blank the correct diameter and with the outer lip radius, and then I cast a couple copies of it in resin.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02838_zps854e2850.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02838_zps854e2850.jpg.html)
The inner fenders with supports and mounting points were made from sheet styrene.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02837_zpse57a3a16.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02837_zpse57a3a16.jpg.html)
After I cut sections of the circular blanks out for each fender and attached them to the inner sections, I bonded the two assemblies together then shaped them as one uniform piece.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02840_zps835a8dd5.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02840_zps835a8dd5.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02839_zps5bce2f03.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02839_zps5bce2f03.jpg.html)

I made some minor modifications to the inner fender panels to allow a little more elbow room for the brake lines that will be added to the calipers later and installed the metal mounting boss.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02841_zps5eb07b71.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02841_zps5eb07b71.jpg.html)
I test mounted the front fenders to the suspension on the car to make sure there is enough clearance for the steering, and to verify it all could be bolted together. It passed…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02845_zps2f882f94.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02845_zps2f882f94.jpg.html)

http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02844_zpscf1851d0.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02844_zpscf1851d0.jpg.html)
I think it is fair to say the majority of the bodywork has been fabricated at this point, but there is plenty more to make too.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02843_zpsa516f43d.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02843_zpsa516f43d.jpg.html)
I think it needs the front spoiler and side bodywork to flow a little better. But then again it is Seven based so a little ungainly is not uncommon…

The wheels are almost done now that they are riveted together. Each one is made up of 23 individual parts. The outer rims are Mazda Tungsten Gray and the centers are a custom mixed dark gunmetal with a cast texture. They still need the brand labeling. Center caps will be made later.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02849_zps58d25757.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02849_zps58d25757.jpg.html)

These are the beginnings of the lower side body panels. Just a little cut, bent and soldered brass…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02851_zps0e803415.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02851_zps0e803415.jpg.html)

The sides will get vents to compensate for not having the louvers in the hood.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02852_zpsb1774847.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02852_zpsb1774847.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02854_zps0807fae4.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02854_zps0807fae4.jpg.html)

The wheels and tires are done (except for the brand labels, wheel weights and center caps).
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02855_zps05c9078b.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02855_zps05c9078b.jpg.html)

The side lower body panels are done enough for the time being…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02857_zpsc6dd3b15.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02857_zpsc6dd3b15.jpg.html)
The left side needs a separate piece to allow for the header to pass through.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02858_zps4ff41297.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02858_zps4ff41297.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02859_zps870087a1.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02859_zps870087a1.jpg.html)

Most excellent building!

The roll bar is made of solid brass rod. I spot annealed the areas I bent the main bar.
Still need to do some detail clean up on the mounting plate soldering…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02890_zps04b7db8c.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02890_zps04b7db8c.jpg.html)
Before I built the roll bar I attached two bosses as receivers to the rear mounting points of the frame.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02889_zps4aa6f47f.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02889_zps4aa6f47f.jpg.html)
I also drilled through the rear body section at the same points and lined the holes with brass tubing for a positive fit and to protect the future paint from chipping during assembly.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02888_zps0ba15572.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02888_zps0ba15572.jpg.html)
It plugs right in…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02886_zpsd4a44a3d.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02886_zpsd4a44a3d.jpg.html)

I've been reading parts of this build, but what an awsome job you are showing. This is far beyond my skills...

Keep up the good work.

The front sway bar and the stabilizer links (including the bushings) are in the bag. Too many tiny parts I didn’t want to risk losing. Mostly brass with some machined aluminum for the nuts & bolts & washers and soft vinyl for the rubber bushings.
I also added the tabs for the stabilizer links to the lower control arms.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02896_zpsd22e6ef8.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02896_zpsd22e6ef8.jpg.html)

I added the seat mounting rails to the frame.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02892_zps55573030.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02892_zps55573030.jpg.html)
And I made the brackets for the seats. This is the left, hence the engraved “L”…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02895_zps23217351.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02895_zps23217351.jpg.html)
The seats snap onto the rails and allow the seats slide.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02893_zpsb999b64f.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02893_zpsb999b64f.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02894_zps6f93085f.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02894_zps6f93085f.jpg.html)