UPDATE – A new Duratec version of the manual has been created. A New Duratec Build Manual
Flicking trough the build manual this evening I found a few observations which might help a novice builder. These observations are relevant if you are building a 270/310 model.
| Manual Build Step | Observations |
|---|---|
| Front wishbones | |
| Steering rack | |
| Front dampers | |
| Front uprights | |
| Headlights and front indicators | |
| Front anti roll bar | |
| Front brake hoses | |
| Horns | Drilling the hole for the 420 horns is easier before the steering rack is fitted |
| Radiator and cooling fan | Leave until after the engine is installed – easy to damage |
| Heater | Leave until after the engine is installed – easy to damage |
| Air box / Air filter housing | Leave until after the engine is installed – easy to damage |
| Remove bellhosuing | |
| Fit bellhosuing to gearbox | |
| Fit gearbox to engine | |
| Install engine and gearbox | |
| Fit some of the engine coolant hoses | |
| Coolant expansion bottle | |
| Fit more coolant hoses | |
| Fuel supply hose to engine | |
| Throttle cable | |
| Clutch hose | |
| Battery and engine earth leads | |
| Fit more coolant hoses to heater | |
| Fill coolant | |
| Air box hose | |
| Steering column and wheel | |
| Exhaust primaries and collector/cat | |
| Hand brake and cable | |
| Prop shaft | |
| Diff | |
| Dedion brake hoses and lines | |
| Dedion tube into chassis | |
| Rear dampers and brake hose to chassis | |
| Rear radius arms | |
| A frame | |
| Rear anti roll bar | |
| Drive shafts | |
| Rear hubs and callipers | |
| Speed sensor | No mention of earth mod, although still supplied in my kit |
| Fit front wheel arches | |
| IVA trim front wheel arches | Easier before the front arches are fitted |
| Rear arches | |
| Rear arch protection | Easier before the rear arches are fitted |
| Front side repeaters, number plate lamp and rear lights | Front side repeaters are easier to fit before front arches are fitted |
| Fuse box cover, knee panels and rivet side panels | |
| Carpet tunnel side panels | |
| Carpet boot floor, fit fuel filler cover and handbrake cover | |
| Tunnel cover | |
| Seat belts | |
| Seats | |
| Roll Bar | This is not possible after rear dampers are fitted; this should be fitted before the rear dampers |
| Exhaust and cat heat shield | |
| Nose and bonnet | |
| Wipers arms and blades | |
| Wing IVA spec mirrors | |
| Starter Motor wiring |
| Things that don’t appear to be covered by the manual at all |
|---|
| Washer bottle fitting |
| Catch tank fitting |
| Engine loom connection to chassis loom |
| Engine temp sender (in submarine for gauge) connection |
| Reverse light switch connection |
| Gearstick installation |
| Gear knob install |
| Rear brake line bending and connection to rear callipers |
| Bleeding the clutch |
| Rear Badge / Sticker location |
| Aero Screen and mirrors |
| Rear view mirror |
| Bonnet / nose protection foam |
| Complete boot and rear panel carpet fitting |
Caterham 420 Detailed Build Blog 