I’d consciously gone into the PBC with an attitude of “95% is close enough, and I’ll let Caterham finish up” for some aspects of the build. The alternative would be to spend more build days/weekends tweaking the last few jobs when I wasn’t really sure what 100% looked like anyway in most cases, so there was no guarantee the result would be any different.
I’d also found myself getting a bit fatigued by the last few prep jobs – having to balance the build against other commitments – and I want to get the car out on the road so I could enjoy it.
Consequently, I was expecting a few items to be identified in the PBC, and Caterham duly obliged. I then had a polite email back-and-forth with Caterham South around items that were definitely on me, and what Caterham would address free of charge.
The results are in…
Items highlighted as IVA concerns (i.e. at my expense to fix):
“Engine wiring loom not correctly routed and not secured every 300mm. Includes routing coolant hoses correctly and horn wiring”
Not surprised about this one, but it was the largest job identified in terms of time to be billed. My main issue with this is that wiring is not covered anywhere in the manual. I pushed back and Caterham South said that it is covered in the IVA guide (one low-res photo), but relented after another (polite) email, and reduced the cost.
“Both front indicator wiring looms need to be secured to the front suspension”
Not sure I’d actually seen this anywhere in the IVA guide, but it was only a quick job, so I didn’t challenge it.
“Rotate radiator fan is it is fitted upside down as per the guide”
Hadn’t realised there was an up/down. There is a ‘technician tip’ in the manual though that the fan may have a flat section which should go at the top. Think I just missed this. Another quick job though.
“Academy oil breather pipes are too long and the overfill pipe is missing”
This is not covered in the manual. I had asked Derek about this, and thought I had followed the guidance I was given, so Caterham agreed to reduce this as well.
“Tail lamps loose”
Think I just didn’t tighten these sufficiently as I was concerned about putting too much pressure on the lamps and wheel arch bodywork. I figured they were better under-tightened than over-tightened. Another quick job, with the time reduced by Caterham as a goodwill gesture.
“‘A’ frame is not aligned correctly”
Not surprised by this one either. I had measured this repeatedly, but wasn’t sure I had enough washers fitted. Happy for Caterham to properly align this.
“Speed sensor needs to be secured to radius arm as per the guide”
It was secured, but apparently not satisfactorily. Quick fix though.
“Front brake callipers leaking (suspect copper washers not central on the caliper); “T” piece at rear leaking; Rear brake hoses twisted and leaking to include brake bleed”
Not at all surprised by this (I’d reported this in my feedback). Tightening and bleeding the brakes were the bane of my build towards the end. Again, happy for Caterham to resolve and set up properly.
“Handbrake cables need routing correctly as per the IVA guide”
I’d reported this one also as I wasn’t happy with the cable routing (running very close to the driveshafts).
“Both front cycle wings need the cable ties removed and fitting correctly”
This one was annoying, and the second longest job identified. I had deliberately not followed the manual here (choosing to use bighead clasps and cable ties), and it cost me a bit as Caterham insisted that the wings be properly fixed to the stays for the IVA. As I wanted them to organise the IVA, and I’d essentially ignored their instruction, there wasn’t much I could argue with. Unnecessary cost, this one.
“Wrong washers fitted on seat rails (too small)”
Poor guidance in the manual here, and I’d used the washers that were supplied with the seats, but a close look at the manual does show different washers.
Items that Caterham will fix free of charge:
“Part of PBC”
- Mirrors loose
- Steering rack needs to be centralised as the cycle wings are hitting the side skins
- Headlamps need to be tightening and aligned
- Pedal set up required
- Throttle set up required
- All spring adjustors need to be tightened
- Exhaust loose
- Various IVA trims required to be fitted for IVA purposes
“Incorrect size “P” clips used on throttle cable – needs to be secured every 300mm”
Caterham originally wanted to charge for this, but I’d fitted the p-clips supplied, so pushed back on this and Caterham agreed to rectify for free
“Not clear in guide/incorrect in guide, so FOC”
- Bulkhead ground should have a washer fitted underneath the terminal
- Fan brackets should have no washers fitted
- Engine mounting washers are incorrect washer
- Alternator positive lead needs to half a half nylock
Other items (FOC)
- Replace the two bell-housing bolts that had stripped threads with longer bolts
- Helicoil and replace the loose engine mount bolt
- Check and repair the paintwork under the car
All in, not too bad – a bit more than I was expecting (maybe a B-?), but I’d assumed there would be some remediation and ended up with mostly FOC or quick jobs with the exception of the engine wiring and cycle wings. I could have taken the car back to remediate the concerns myself, but at this point, I’m happy to just let Caterham do it and get the car to 100% ready.
Interestingly, rubber piping for the rear fog/reversing lights wasn’t mentioned, so glad I didn’t mess around with that for too long.
Now I sit back, and wait. Caterham will do the remediation and the IVA. I can then get the car registered, and go pick it up.