Build 65. Knee Trim and Fuse Cover

It was time to start finishing off the cockpit area now, and this starts with the knee trims and fuse box. Earlier blogs seem to have trouble fitting these, but Caterham must have changed the design as mine all fit in fairly trivially.

Firstly trim is applied to the edges that need it and glued in place, for the left knee guard nothing needed doing as this will all be covered by the fuse box, however the right hand side one needed trim along its edge as shown in the photo. I also bunged the hole with the big rubber grommet (This doesn't need to be glued as you may need access).

I used Chris Collins trick of using masking tape to mark where the holes were for the screws. This was neat because when you slot it in, the rubber will occlude your view of the holes, so it made lining it all up much easier. Once you have it in place, I cut the rubber to size and then I pre drilled the holes in the rubber (to stop the screws pulling the rubber) and then fixed using the self tapping screws. Once this was done I could use rivets to secure the remaining interior panels.

This was repeated on the RHS as well, but a little bit tighter due to the master switch electrics getting in the way (I bent them up slightly!). I also had to remove my long heater knob aswell to get it in place.

On the left hand side, it was slightly flappy (due to lack of trim) and rattled, so I added some trim between it and the dash to avoid this. This still allowed space for the fuse box to slot in.

Finally I had to trim around the edges of the fuse box, then apply the velcro strips to where it will contact the chassis. I left these for an hour before then dry testing it in position, and then finally fixing the whole unit in place on the left hand side.

Timelapse