Caterham 7 User manual

ASSEMBLY GUIDE
EDITION 1.0

ASSEMBLY GUIDE
EDITION 1.0
Your feedback and comments are welcome: [e-mail]

ASSEMBLY GUIDE
i
Welcome to your new Caterham kit
Building your own Caterham is immensely rewarding and satisfying. Of course, it should be remembered
that you are building a high performance sports car, not a flat-pack wardrobe, so it will be a little challenging
from time to time; but we’ve set out to make it as easy as possible for anyone, whatever their skill level and
help is just a phone call away.
But before you do anything else, pop the kettle on or pour yourself a G&T with a slice; and
READ THE NEXT THREE PAGES – THEY ARE REALLY IMPORTANT
No, they will not be very exciting unfortunately, but they are important nonetheless and you will regret it later
if you don’t.

ASSEMBLY GUIDE
ii
So there are four important things we need to think about NOW before
picking up a spanner:
• This isn't the only guide you'll need
• When to apply for an IVA test
• Photography (no, really)
• Arranging a post build check
Although we have made this guide as comprehensive as possible, the requirements of IVA change from
time to time and even from test centre to test centre. Therefore, it MUST be read in conjunction with the ‘IVA
Checklist Guide’, the latest version of which can be downloaded from the Caterham website. You’ll find the
refer-to-IVA-manual symbol in the bottom of each illustration where attention is required. Reading through
it now, will save pain later! Don’t assume that because you’ve found a reference to one item relating to that
page, it is the only one…
Once you have completed the assembly of your Seven, you are required by law to present it for an ‘Individual
Vehicle Approval’ test (better known as IVA), which is conducted by the Vehicle and Operator Services
Agency (VOSA) at a regional test centre.
We STRONGLY recommend that you apply for your IVA appointment at least a month before you think you
will complete your build, to allow for the application form to be processed at the snail’s pace of bureaucracy.
Once accepted, your IVA application is valid for 6 months and test dates can be changed up to a minimum
of 3 working days prior to your appointment with VOSA (any later and you may incur a charge).
The application form and a guide on how to complete it, is contained within an envelope of documents
provided with your kit and which is probably acting as a coaster for your g&t at the moment. Take this
moment to find it and remove it from the garage and place it somewhere safe (and memorable).

ASSEMBLY GUIDE
iii
VOSA and the DVLA are a suspicious bunch and in order to register your car, you will need to provide proof
that it is amateur built. When you apply for registration, you will need to include photos from various stages
of you build, which will demonstrate to them that it is an ‘amateur build’.
Recruiting a few extras (your kids, your spouse, the cat, etc.) and some props (last year’s Xmas tree, a radio
from the 1980’s and a rusty bike) will all contribute to a more authentic home-garage feel; proving that no
professional help (i.e. commercial workshop/garage) was involved in the build. Of course, feel free to have
yourself working away on the kit in the photos if one of your ‘extras’ can be trusted with the camera (not the
cat; they never get the exposure right).

ASSEMBLY GUIDE
iv
Finally, we know you haven’t started yet, but we need to tell you about the Post Build Inspection now, due to
availability at our service centres and the time it takes to get you a slot. Plan ahead!
What is the Post Build Inspection? This is a free service oered by all Caterham service centres which we
wholeheartedly recommend you take up on prior to your IVA test. It ensures that your car is correctly
assembled and is road-worthy. All safety and operational aspects of your Seven will be checked, concluding
in a road test. This will enable us to advise you of any corrective work that may be required (which we will be
happy to carry out for you*). It is important to note that this is not the same as the IVA test and whilst every
eort will be made to ensure your car passes, there is NO GUARANTEE of a first time IVA pass.
*Obviously any additional work is not for free, but we will speak to you first so you can decide whether you
want to pay us to do the corrections or you want to do them yourself.
REMEMBER: Post Build Inspection slots are in high demand at our service centres and there may be a
two-month lead time at busy times, so please check on availability and book ahead!
All our service centres will be able to oer you a Post Build Inspection and IVA service, where they take the
car to IVA on your behalf. This tends to increase the likelihood of a first time pass and means you don’t need
to take a day out to endure the test, which is beyond dull.
As a guide, the Post Build Inspection through to registration can take around 6 weeks to complete.

v
ASSEMBLY GUIDE
That’s it, we’re ready to start assembly
ENJOY

ASSEMBLY GUIDE
vi
MY BUILD NOTES
Download the IVA Checklist Guide: www.caterhamcars.com
Book IVA Test
Take plenty of photos
Arrange post build check
This was more fun than I ever expected!

1
HINTS & TIPS
When using a torque wrench, listen/feel the click
and then stop. It does not need to be any tighter
and you might actually weaken the fixing by
‘over‑torquing’ it. Always wind your torque wrench
setting back to free when you’ve finished with it.
John K
A ‘caphead bolt’ has a circular head with a hexagonal drive
inside it. It is tightened with an allen key or hex drive socket.
Capheads are useful where there is limited space around
the head for a spanner or socket. They look nice too!
Richard T
Generally, metric Nyloc nuts have a
blue nylon insert and imperial ones a
white nylon insert.
Grant P
You can tell if you have ‘wide track suspension’ car by looking at the front
dampers. Wide track has a 25mm long hexagonal spacer between the top
spring retainer and the mounting bush.
Matt T
A bolt size is described by its diameter (e.g. M10=10mm)
by the length not including the head (e.g. 65mm).
James A
A ‘spring washer’ has a split in it and squashes up
closed when a fixing is tightened. It is usually used
under a bolt head to help resist it coming undone.
John S
A ‘nyloc’ nut is one with a nylon insert that gets cut by the bolt
thread, making it resistant to unwinding itself. This means that
they should not be repeatedly re‑used.
Chris B
Thread lock is used to stop
something coming undone, but
it only needs a little drop on
the thread to be effective.
Jamie A
Teabag, boiling water, then the milk, in that order.
Simon L
Left and right are as viewed
from the driver’s seat.
Harrison P
1Nm of torque equals 0.736lbft.
Mick F
When using a spanner, always use the ring end wherever
possible. The open end is really only for those times that access
is too limited for a ring spanner or socket.
Mick A
ASSEMBLY GUIDE

ASSEMBLY GUIDE
2
KEY
SYMBOLS
Repeat on other side
Required torque (where applicable)
S3 / S5 chassis specific instructions
S Pack / R Pack
specific instructions
Fixing item
Item number Advice from factory
professionals
Now is a good time to take
some photos
Reminder to apply for your IVA test
Refer to IVA Checklist Guide
AA
AJ
AM
S3
S5
35
mm
35
mm
Nm
1
FIXINGS
PART
NUMBER QTYUSED ON
1AABM12X100 2Lower wishbone
rear
2ABBM12X652Lower wishbone
front
3ACBM10X65 2Upper wishbone
rear
4ADBM10X60 2Upper wishbone
front
5AEBM8X40 4Anti-roll bar
mounting brackets
6AFNMPH14 1
Temporary use to
help lock upper
wishbone ball joint
7AGNMYF12 2Lower wishbone
rear
8AHNMYF10 4Upper wishbone
9AJWPCM12 18 Lower wishbone
10 AK WPHM84Anti-roll bar
mounting brackets
11 AL WPH3/8 2Brake pipe
Drawings are for illustrative purposes only and are not to scale.
ASERIAL
NUMBER 44
Pack PACK NUMBER
30F015B
FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options
ITEM BASIC
DESCRIPTION ILLUSTRATION
Bolt M12 x 100
Grade 10.9
Bolt M12 x 65
Grade 10.9
Bolt M10 x 65
Grade 10.9
Bolt M10 x 60
Grade 10.9
Bolt M8 x 40
Grade 10.9
Plain Nut M14
x 1.5 thread
Nyloc Nut M12
Plain Washer
⅜" x ¾"
Heavy duty
Page 1 of 2
Nyloc Nut M10
Plain Washer
M12
Chamfered
Plain Washer
M8
Heavy duty
PART
NUMBER QTYUSED ON
1AABM12X100 2Lower wishbone
rear
2ABBM12X652Lower wishbone
front
3ACBM10X65 2Upper wishbone
rear
4ADBM10X60 2Upper wishbone
front
5AEBM8X40 4Anti-roll bar
mounting brackets
6AFNMPH14 1
Temporary use to
help lock upper
wishbone ball joint
7AGNMYF12 2Lower wishbone
rear
8AHNMYF10 4Upper wishbone
9AJWPCM12 18 Lower wishbone
10 AK WPHM84Anti-roll bar
mounting brackets
11 AL WPH3/8 2Brake pipe
Drawings are for illustrative purposes only and are not to scale.
ASERIAL
NUMBER 44
Pack PACK NUMBER
30F015B
FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options
ITEM BASIC
DESCRIPTION ILLUSTRATION
Bolt M12 x 100
Grade 10.9
Bolt M12 x 65
Grade 10.9
Bolt M10 x 65
Grade 10.9
Bolt M10 x 60
Grade 10.9
Bolt M8 x 40
Grade 10.9
Plain Nut M14
x 1.5 thread
Nyloc Nut M12
Plain Washer
⅜" x ¾"
Heavy duty
Page 1 of 2
Nyloc Nut M10
Plain Washer
M12
Chamfered
Plain Washer
M8
Heavy duty
x4 (Indicates number of each fixing required)
(Greyed out area indicates fixings are not
required for current step)
REPEAT

ASSEMBLY GUIDE
3
TOOLS
KEY
Spanner
Scissors
Grease
Latex gloves
Junior hacksaw
Long nose pliers
Pop rivet gun
Muscle
Pozidrive
screwdriver
Power adhesive
Flat head
screwdriver
Thread lock /
LocTite
LOCTITE
LOCTITE
Tape
Torx
Tape measure
Trolley jack
Torque wrench
WD40
Ruler
Side cutters
Silicon gun
Silicon
Socket wrench
Spray adhesive
Spray lube
Socket wrench
(allen)
Stanley knife
Spirit level
Drill bit
Axle stand
Combination
spanner
Allen key
Engine hoist
Copper grease
Drill
Cable tie
Assistance
+

ASSEMBLY GUIDE
4
LET’S GET READY
PARTS
FIXINGS
TOOLS
TIPS
x3
When deciding how high your axle stands
should be (the higher the better for working
on), don’t forget that a complete car will
need to come down off them, so make sure
your trolley jack can reach and lift the
height you set them too!
Mick F
Some tape or foam on the
top of the axle stands will
stop them scratching the
chassis.
Matt T

ASSEMBLY GUIDE
5
LET’S GET READY

ASSEMBLY GUIDE
6
START WITH THE SUSPENSION WISHBONES
PARTS
FIXINGS
TOOLS
TIPS
PART
NUMBER QTYUSED ON
1AABM12X100 2Lower wishbone
rear
2ABBM12X652Lower wishbone
front
3ACBM10X65 2Upper wishbone
rear
4ADBM10X60 2Upper wishbone
front
5AEBM8X40 4Anti-roll bar
mounting brackets
6AFNMPH14 1
Temporary use to
help lock upper
wishbone ball joint
7AGNMYF12 2Lower wishbone
rear
8AHNMYF10 4Upper wishbone
9AJWPCM12 18 Lower wishbone
10 AK WPHM84Anti-roll bar
mounting brackets
11 AL WPH3/8 2Brake pipe
Drawings are for illustrative purposes only and are not to scale.
ASERIAL
NUMBER 44
Pack
PACK NUMBER
30F015B
FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options
ITEM BASIC
DESCRIPTION ILLUSTRATION
Bolt M12 x 100
Grade 10.9
Bolt M12 x 65
Grade 10.9
Bolt M10 x 65
Grade 10.9
Bolt M10 x 60
Grade 10.9
Bolt M8 x 40
Grade 10.9
Plain Nut M14
x 1.5 thread
Nyloc Nut M12
Plain Washer
⅜" x ¾"
Heavy duty
Page 1 of 2
Nyloc Nut M10
Plain Washer
M12
Chamfered
Plain Washer
M8
Heavy duty
94
PART
NUMBER QTYUSED ON
12 AM WSHM12 2Lower wishbone
front
13 AN WSHM86
Anti-roll bar
mounting brackets &
upper damper
mount
14 AP WSS3/8 2 Brake pipe
15 AR NFYH1/22Wing stay
16 AS NFYF1/22
Front brake, upright
mounting (std track
ONLY)
Drawings are for illustrative purposes only and are not to scale.
ASERIAL
NUMBER 44
Pack PACK NUMBER
30F015B
FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options
ITEM BASIC
DESCRIPTION ILLUSTRATION
Spring Washer
M12
Nyloc Nut ½"
Full height
Page 2 of 2
Spring Washer
M8
Washer ⅜"
Shake-proof
Nyloc Nut ½"
Half height
x2
x2
x2
x2
x2
x4
x14
x2
17mm
19mm
Lower wishbone
Wishbone bush sleeve
Upper wishbone
17mm
19mm
1
3
2
For now, only tighten the nuts/bolts lightly and then
torque them up when the car is finished and on the
ground. This sets the bushes correctly and ensures
the best handling.
Harrison P
The big washers are chamfered and
the chamfered side should be towards
the wishbone.
Alex H
Leave bolt AD
loose for now,
as we have to
take it back out
again to put
the headlight
bracket on later.
John K

ASSEMBLY GUIDE
7
START WITH THE SUSPENSION WISHBONES
35
mm
35
mm
81Nm
AB
AJ
AM
1
2
3
AJ
35
mm
35
mm
81Nm
AA
AJ
AG
35
mm
35
mm
47Nm
35
mm
35
mm
47Nm AD
AH
AC
AH
REPEAT

ASSEMBLY GUIDE
8
NOW FOR THE STEERING RACK
PARTS
FIXINGS
TOOLS
TIPS
PART
NUMBER QTYUSED ON
1BABMCH6X70 4Rack clamps
2BBBF1/4X1.1/2 2Column clamp
3BCBM8X35 2Column to rack
universal joint
4BDNFYH1/21Steering wheel boss
5BENFPF1/22Track rod lock nut
6BFNFPFH7/161Column clamp
grubscrew locknut
7BGNMYF8 2Column to rack
universal joint
8BHNMYF6 4Steering rack
clamps
9BJWPH1/2 1Steering wheel boss
10 BK WPH1/4 6Rack clamps and
column clamp
11 BL WSH1/4 2Column clamp
Drawings are for illustrative purposes only and are not to scale.
BSERIAL
NUMBER 55
Pack PACK NUMBER
30S003B
STEERING DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options
ITEM BASIC
DESCRIPTION ILLUSTRATION
Caphead Bolt
M6 x 70
DIN 912
Bolt ¼" x 1½"
Bolt M8 x 35
Grade 8.8
Nyloc Nut ½"
Half height
Plain Nut ½"
Plain Nut ⁷⁄₁₆"
Half height
Nyloc Nut M8
Spring Washer ¼
Heavy duty
Page 1 of 1
Nyloc Nut M6
Plain Washer
½" x 1⅛"
Chamfered
Plain Washer
¼"
Heavy duty
x4
x2
x2
x2
x4
x4
10mm
13mm
Steering rack
Column universal joint
Rack clamps
IVA cover
Track rod end
5mm
13mm
22mm
¾"
1
3
2
5
4
Finding the right IVA cover isn’t
obvious because it is effectively
a long cap. To use it, you cut the
closed end off.
Jamie A
The trackrod end needs to screw on
about 12 turns (it will be properly set
later when the tracking is done).
Matthew H

ASSEMBLY GUIDE
9
NOW FOR THE STEERING RACK
35
mm
35
mm
11Nm
BE
3
5
35
mm
35
mm
20Nm
BC
BG
BH
BK
BA
2
1
4

ASSEMBLY GUIDE
10
PART
NUMBER QTYUSED ON
1AABM12X100 2Lower wishbone
rear
2ABBM12X652Lower wishbone
front
3ACBM10X65 2Upper wishbone
rear
4ADBM10X60 2Upper wishbone
front
5AEBM8X40 4Anti-roll bar
mounting brackets
6AFNMPH14 1
Temporary use to
help lock upper
wishbone ball joint
7AGNMYF12 2Lower wishbone
rear
8AHNMYF10 4Upper wishbone
9AJWPCM12 18 Lower wishbone
10 AK WPHM84Anti-roll bar
mounting brackets
11 AL WPH3/8 2Brake pipe
Drawings are for illustrative purposes only and are not to scale.
ASERIAL
NUMBER 44
Pack
PACK NUMBER
30F015B
FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options
ITEM BASIC
DESCRIPTION ILLUSTRATION
Bolt M12 x 100
Grade 10.9
Bolt M12 x 65
Grade 10.9
Bolt M10 x 65
Grade 10.9
Bolt M10 x 60
Grade 10.9
Bolt M8 x 40
Grade 10.9
Plain Nut M14
x 1.5 thread
Nyloc Nut M12
Plain Washer
⅜" x ¾"
Heavy duty
Page 1 of 2
Nyloc Nut M10
Plain Washer
M12
Chamfered
Plain Washer
M8
Heavy duty
94
PART
NUMBER QTYUSED ON
12 AM WSHM12 2Lower wishbone
front
13 AN WSHM86
Anti-roll bar
mounting brackets &
upper damper
mount
14 AP WSS3/8 2 Brake pipe
15 AR NFYH1/22Wing stay
16 AS NFYF1/22
Front brake, upright
mounting (std track
ONLY)
Drawings are for illustrative purposes only and are not to scale.
ASERIAL
NUMBER 44
Pack PACK NUMBER
30F015B
FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options
ITEM BASIC
DESCRIPTION ILLUSTRATION
Spring Washer
M12
Nyloc Nut ½"
Full height
Page 2 of 2
Spring Washer
M8
Washer ⅜"
Shake-proof
Nyloc Nut ½"
Half height
AND THEN THE DAMPERS
PARTS
FIXINGS
TOOLS
TIPS
6mm
Spring / damper
Upper damper eyelet
Lower damper eyelet
6mm
6mm
1
3
2
Put the top of the damper on first
and be careful not to let it swing into
the side of the chassis.
Grant P
The bottom can be a tight fit!
Mick F
x2
Fixings not contained in the pack will be
supplied loosely fitted to the chassis and
the wishbone

ASSEMBLY GUIDE
11
7
7
AND THEN THE DAMPERS
35
mm
35
mm
25Nm
1
2
3
35
mm
35
mm
25Nm
AN

ASSEMBLY GUIDE
12
PART
NUMBER QTYUSED ON
1AABM12X100 2Lower wishbone
rear
2ABBM12X652Lower wishbone
front
3ACBM10X65 2Upper wishbone
rear
4ADBM10X60 2Upper wishbone
front
5AEBM8X40 4Anti-roll bar
mounting brackets
6AFNMPH14 1
Temporary use to
help lock upper
wishbone ball joint
7AGNMYF12 2Lower wishbone
rear
8AHNMYF10 4Upper wishbone
9AJWPCM12 18 Lower wishbone
10 AK WPHM84Anti-roll bar
mounting brackets
11 AL WPH3/8 2Brake pipe
Drawings are for illustrative purposes only and are not to scale.
ASERIAL
NUMBER 44
Pack
PACK NUMBER
30F015B
FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options
ITEM BASIC
DESCRIPTION ILLUSTRATION
Bolt M12 x 100
Grade 10.9
Bolt M12 x 65
Grade 10.9
Bolt M10 x 65
Grade 10.9
Bolt M10 x 60
Grade 10.9
Bolt M8 x 40
Grade 10.9
Plain Nut M14
x 1.5 thread
Nyloc Nut M12
Plain Washer
⅜" x ¾"
Heavy duty
Page 1 of 2
Nyloc Nut M10
Plain Washer
M12
Chamfered
Plain Washer
M8
Heavy duty
94
PART
NUMBER QTYUSED ON
12 AM WSHM12 2Lower wishbone
front
13 AN WSHM86
Anti-roll bar
mounting brackets &
upper damper
mount
14 AP WSS3/8 2 Brake pipe
15 AR NFYH1/22Wing stay
16 AS NFYF1/22
Front brake, upright
mounting (std track
ONLY)
Drawings are for illustrative purposes only and are not to scale.
ASERIAL
NUMBER 44
Pack PACK NUMBER
30F015B
FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options
ITEM BASIC
DESCRIPTION ILLUSTRATION
Spring Washer
M12
Nyloc Nut ½"
Full height
Page 2 of 2
Spring Washer
M8
Washer ⅜"
Shake-proof
Nyloc Nut ½"
Half height
IT’S TIME FOR THE WINGSTAYS
PARTS
FIXINGS
TOOLS
TIPS
19mm
22mm
¾"
22mm
Wingstay
Front brake & upright assembly
x2
x2
1
2
Some of the fixings
required and shown
on the drawings,
such as the ball
joint nut, are already
on the part and not
in the fixing pack.
Anthony L
Use the plain
nut to pull the
top ball joint
home before
using a nyloc,
otherwise the
thread will spin.
Chris N
The drilled hole is for the side repeater earth that we’ll fit later. It’s easier to
drill from the top and down through both sides of the tube, rather than through
one side from the bottom (where the earth will be fixed).
Tiago O
Put the ‘upright’ into the lower
wishbone joint then attach
the steering before tightening
the bottom nut. This stops it
all swinging around hitting the
side of the chassis.
John S
"