Build Day 20: Boot carpet, Washer Bottle and Differential Oil fill

We are nearing the end of the build now and one of the last jobs is to fill the differential with oil. The oil is supplied with the kit and no additive is required either. The differential fill plug is not easy to get at so I lifted the aluminium honeycomb panel to get access.

I made up a filling tube and funnel which I attached to the rollbar with masking tape. The differential requires 0.8L and so I gradually filled it up letting gravity do the work. The oil stinks of sulphur so I was very careful not to spill any and left the tube in place for 30mins to ensure it all drained through before refitting the drain plug and closing up the boot.

Washer Bottle: The washer bottle can either be fixed to the side panel or the petrol filler tube cover – I chose the latter as this is how Caterham do it on their factory productions cars. After carefully measuring the height of the bracket we drilled holes for the bracket, washer pipe and electrical connections. Most of the wiring and tubing is tucked behind the filler cover and I used a couple of rubber grommets to prevent chaffing of the electrical and washer pipe. The cover is simple screwed into the honeycomb floor (unfortunately I had no option but to use a couple of self-tapping screws)

Boot Carpet: The carpet is pre-cut in several sections including a set of triangular pieces for the rear bulkhead which I chose not to fit. I used the same contact adhesive as for the tunnel carpet and after some trimming with a Stanley knife I got the panels to fit to my satisfaction. I left the boot floor carpet loose as I may need access to the handbrake adjuster under the wooden part of the boot floor later.

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