Fitting the heater after the engine install. Also fitting the oil catch tank, which is not mentioned in the assembly guide
Heater :
Start by loosening the battery, you may need to slide it forward very slightly to get the heater to fit between the car body and the battery itself.
The heater is supplied in its own box fully assembled. Get it out and seperate the two pieces.
Find a suitable grommet from the grommet pack, check that it fits the hole in the car first. Again the caterham supplied ones are a little on the small side. You need to cut this grommet on one side, wrap it around the wire coming out of the heater and use some superglue to make the grommet again.
Now place the internal piece of the heater inside the car – make sure that the two protrusions are facing downwards as this will vent hot air toward the feet.
Put the heater in place in the engine bay, then pass through the bolts from inside the car. You may need to use some pin punches to sit the bolts properly and it can take a bit of wiggling but it will all fit. Then loosely tighten from the outside. The manual calls for a washer under the top screw. I couldn´t find this is any pack so I fitted a spare M5 washer. When you tighten it up, don´t do it too tight. It won´t stop naturally so you risk cracking the plastic if you are not careful.
Remove the two black rubber bungs from the heater pipes and discard as per the manual. This can be fairly tough to do but it will come off eventually.
Fit the heater cable into position which moves from the LHS side behind the battery to the RHS of the car. Get the heater valve and clamp this to the heater cable, using a 1/4 inch socket to tighten up and hold in position. The manual has you drilling a small hole in the bottom of the heater, then using a rivet to attach a cradle clip and then using a zip tie to pull the cable closer to the heater. I chose not to drill this hole, saw a factory built car without this clip and the probability of something going wrong is too high.
From the cooling box, get the 5/8inch hose which is wrapped in a coil and marked HEATER HOSE. Cut two lengths, 11cm and 12cm. Use some masking tape wrapped around to help track where to cut using a stanley knife.
Fit these lengths to the bottom (11cm) and top (12cm) pipes in the heater, push them all the way onto the pipes and then add a hose clip to each. Be careful not to tighten the hose clip too much, you don´t want to damage the copper pipe!
Once done, slide two more clips over the lengths of heater hose, before using some rubber lubricant to push the heater valve into place. Again push it on a decent amount before tightening up the hose clips, finishing the heater.
Oil Catch Tank :
This is not mentioned anywhere in the guide. You will notice two pre-fitted hoses coming from the engine when it arrives, these two hoses go into the Oil catch tank which sits in the front LHS just above the Steering rack.
Start by taking the bracket from the cooling box, and drilling out two relevant holes to 4mm. Make sure you are using a quality HSS (High speed steel) drill bit.
Now on the car the nerve wracking bit, you need to use the drill to drill out a rivet. Being new to rivets, I found this intro very good which explains everything you need to know about installing and removing rivets.
Using a 2.5mm drill bit at first, followed by a 4mm drill bit, very carefully drill out the front rivet on the LHS of the car.
Once done, get some masking tape onto the bodywork and offer up the mounting plate. Mark the rear most hole and drill that out to 4mm also.
Now offer up the bracket, again be very careful to get it the correct way up, and put two 4mm rivets through the gaps and then use the rivet pop gun to attach.
Finally test fit your Oil catch bottle to ensure it fits.
