Build 70. Floor Mats

I first did a dry fit with both mats in the footwell and it is easy to see that the mats don't quite fit the lowered floors. I decided that rather than cut them to size I'd simply let the sides of the mat curve upwards and leave the sides near the tunnel nice and straight. They should just eventually naturally bend to the curve on the edge anyway and if they don't I can always trim them later! Once I was happy with the placement I worked out where to place 3 press studs to fix them into place and used a hole punch to cut them out.

I then placed each mat back inside the cockpit exactly where I wanted them and then used my drill to mark a small position for each popper base to go. I then took the mats out and drilled a 4mm hole in the locations marked ready for the popper bases.

the popper bases were simply riveted into place, I had to use a small nyloc nut in the base so the rivet gun actually worked properly. Caterham also supply a tool (as pictured above) to help attach the popper head to the mats. I found I had to really hit the hammer hard as the mat was quite a thick piece of rubber to get the poppers through.

I was going to stop here, but then once I placed them in the car, the poppers sat slightly high and you could see the mat sagging onto the floor below (see 2nd picture below). I had some Duramat left over so I used this underneath the mat and then once I put the mat back down the sagging was gone.

Timelapse