Build 4. Steering Rack
A much nicer job after the tight fitting wishbones, I'm building a 420R, and this means you need to drill a hole read for the horn (I think this is shown on page 18 of the manual), this can be done after, but I figured why wait, it is an 8mm hole, and drills super easy.
Next up I gathered together all the parts. I've got a system for all this now, basically I gather all the parts needed, put them in a box and label it up. Any parts left loose in bags get stored this way too so I can keep track of where all the parts are, I've got a whole load of these boxes, and I am storing all the parts in the top part of my Sealey work area.
On with the fitting of the rack, It's a pretty simple task, It reminded me of putting together our table football table. Feed one end in from the inside, through the steering rack hole, and then feed it through enough that you can then put the other end through the other hole.
I used a cloth to avoid scratching the area it will be attached to. put the two clamps in place and loosely tighten it all up, it will need to be adjusted when the steering column goes in later.
I found that then attaching the steering universal joint was a fun job, mine seemed to fit just fine, and actually after looking at the part, it is differently made to the other blogs which have has trouble. I guess Caterham have decided to get a joint that works. For the record mine looked like this:
You can torque this up fully, and then mark the bolt with a pen so you never have to touch it again. I then loosely fitted the bolt in the other part for later. (I've also noticed that this requires 32Nm torque, and not 20Nm which other blogs mention, I guess this is due to the different part)
Next up make sure you grab the IVA trim which will cover the tracking bolts, this was in my bag of general rubber trim with grommets etc, and the actual pieces had the word "Low Smoke" written on them, which came off easily with WD40 and a cloth, you also need to trim off the closed end with a knife. Slide these on and then get ready to put the track rod ends on.
The track rod ends simply screw on, make sure to put the locking nut on first too, they will be adjusted at the PBC for the correct tracking, but for now turn them on 12 turns, hand tighten the locking nut and then put the IVA trim over it all.
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