MY CATERHAM 7 BUILD

[78Brougham]

Got all the fluids in and now time to start the interior. I installed the hand brake and covers for the tunnel by riveting the black cover parts in place. Of course with a 50-50 chance of putting the wires on the micro switch for the brake light I was wrong! Had to fish my hand down in and reverse the wires! Wish the instructions were a bit more explanatory!

Glued the carpeting in with 3M spray glue...

Then fitted the beautiful leather seats and tunnel cover and MOMO quick release steering wheel. The steering column shaft was a real SOB! Did that previously, but the bushings just behind the dash were a real bear! I must have pushed them through a dozen times before I got it right!

Time to move on to the front cycle wings and rear wings (fenders to you and me)
I installed the headlights first and then the front wings needed to be glued to the supports that are mounted to the spindle/caliper brackets. I used a 2 part epoxy that my body shop customers use for bonding body panels together instead of welding.
The headlights obviously remain stationary but the cycle wings turn when steering. Very cool, and its cool to see them move up and down when driving.

Before I mounted the wings, I took them to a customer of mine that does bed liners. I had him put it on the underside of the fenders to help protect them from rocks flinging off the tires. I live on a macadam road and travel on some dirt roads occasionally.

The rear fenders are bolted on with a rubber bead in between them and the body.

 

[Marv]

Great work and I can imagine that these types of cars are the most fun you can get on 4 wheels with that HP/weight ratio.
More fun than a heavy Lamborghini etc.

There's a Dutch company named Donkervoort. They also build such cars currently with an in line 5 cylinder putting out more than 350hp. I would probably kill myself with such a missile

 

[78Brougham]

Mounted up the tail lights and put on the stainless steel chip guards.

Meanwhile, it took quite a while to figure out why it wouldn't start. After multiple back and forth's with the factory, I discovered that they had 2 relays reversed. There are only 4 relays on the fuse panel. The one for the 4 ways was where the starter relay was supposed to be. Of course one of them burned out due to power being applied in the wrong spots! Once I figured that out, "Ruby" fired right up! Talk about a great day!!!!
3/30/2019

Installing the side stripes you see above was a bit of a challenge but not that bad. I'm still waiting for the hood stripes though... Dealer promised me they would be here soon!

After waiting for decent weather, I finally gave up and took it no matter the weather. I had to have an "Enhanced Inspection" done on the car because it is a "Specially Constructed Vehicle". No big deal as the folks that did it are my customers and they have been kept abreast of everything I've done on the car.. They also have a notary service so they handled all the paper work and the PENNDOT licensing procedure pictures etc.
Well we thought all was good but after over a month and a trip to my local State representative, I finally found out what the hang up was and they returned my application
Of course they cashed my $1800 check for the sales tax and registration fees the first week!

Apparently, someone in Harrisburg was having a bad hair day, and rejected it because there was no license plate frame. Ummm excuse me but don't I need a license plate to put a frame around it? And they didn't like that the super cool chrome tuned exhaust pipes were exposed! Ummm aren't there exposed exhaust pipes on just about every Harley on the planet???

Undeterred I had to think of something without destroying my car. So after a driving on a long trip to Buffalo with plenty of time to think I came up with a plan.
First I borrowed the frame from Sammie's MINI.

And for the exhaust which was the real problem.... A trip to Lowe's, some flexible 6" aluminum ducting, the magic of scissors and PRESTO!

I sent them these pictures via my local State Representative's Diplomatic Pouch and I had my Plate within the week!

Of course that tin plated crap was off of there quicker than you could say it!

Finally on the road legally on 6/22/2019!!!!

 

[78Brougham]

There's a Dutch company named Donkervoort.

I'm familiar with them. Very Very Cool!!! Out of my league though. Plus I'm a Lotus guy and what better way to celebrate their heritage than to get one of these for the collection.

 

[saforwardlook]

That is a very cool vehicle, and I like the out of the box thinking that goes into owning and building one of these.

That is what keeps you young!!!

Kudos to you Kenny!

 

[78Brougham]

Here it is with my wife and best friend Sammie at the Seneca Lodge in Watkins Glen.She's the one who persuaded me to buy and build this. She's the BEST!

We were there last September for the Vintage Gran Prix. Hung out with some of our Lotus Buds

Check out how small the car is compared to my friends Monte Carlo SS.... LOL

Even though there was some stress and aggravation, I would do it again in a heartbeat. It would go soooo much quicker.

It was a very gratifying experience to build something like this.

Thanks for indulging me and all the props!

 

[saforwardlook]

I always love hearing someone say that their wife is also their best friend. Her encouragement, support and involvement make that clear. You have made some wise choices. Enjoy to the fullest, both of you!

 

[live4theking]

Very cool to see it finished up. It's great that Sammie gave you the nudge to do it also.

 

[twostick]

Nice job!!!

Can you share the ballpark price of that?

That power to weight ratio is a definite smile generator. Was there not a version of that with a 3.5L Rover/Buick aluminum V8 in it? That V8 sound would finish checking all the boxes.

It kind of puts me in mind of an Allard J2 that was washed in hot water and put in the dryer.

Kevin

 

[Fratzog]

Late to this thread but thanks for sharing the story. The car looks like a blast to drive. I'm sure you will have fun with it as soon as the weather breaks.

 

[78Brougham]

Nice job!!!

Can you share the ballpark price of that?

That power to weight ratio is a definite smile generator. Was there not a version of that with a 3.5L Rover/Buick aluminum V8 in it? That V8 sound would finish checking all the boxes.

It kind of puts me in mind of an Allard J2 that was washed in hot water and put in the dryer.

Kevin

Oh it sounds pretty good, nowhere as deep as a V8 but pretty entertaining.

They're not too bad even with the S Pack and a few upgrades let's just say you couldn't get a decent pickup for what I've got into it. And they hold there value extremely well.

 

[78Brougham]

Got this cool sticker and put it on the dash... LOL

Here's a couple commercials for Caterham they have in England. Luckily someone here copied the sticker!

 

[saforwardlook]

Are you ever going to grow up?!!!

I hope not!! And she is hot! And the car too...............

 

[78Brougham]

We took Ruby to Hammondsport NY, back in September for the annual "Wings and Wheels" car show on Keuka Lake in NYS. Second time we've been there. It's a really cool festival of all kinds of Seaplanes and Cars. Pretty tough competition...

Father and son team own these Challengers. Very cool guys!

The Ferrari and the McLaren below are owned by the same guy. He's an executive at Corning Glass. Don't get your claws out... Him and his wife are actually very down to earth. Was very nice talking to them!

 

[78Brougham]

Here's another project car that I picked up a few years ago. Got it CHEAP! But just like most of our C-bodies its not worth much even though the production numbers are unbelievably small.
This car was designed in 1974 as Lotus was trying to move more upscale and create a market for more of a family sports car. They came up with the Lotus Type 75. The Elite. They were produced from '74-'84, and only about 2500 were ever produced. The model I have is called a 503. A 501 was base, the 502 had power steering, the 503 had power steering and AC and the 504 was power steering, AC and Automatic. All were powered by the 907, 2.0 Lotus 4cyl. engine, which wait for it.... became the basis for the Chrysler 2.2 a few years down the road. At this point it made 144 HP. Which was bad considering a 318 of the same era was making 150.

Anyway, there were only approximately 300 of brought into the states in that 10 year period and I, after purchasing a couple more from a friend of mine here in town own 3! It was a labor of love for one of the weirdest Lotus cars ever designed. I don't know what they were thinking but I know what I think.... GREMLIN!

But... It handles Waaaaaaaaaaaaaaaaay better and drives Waaaaaaaaaaaaaay better .. LOL

Took me about 4 years to get it on the road but I did it!
I bought it out of Cortland NY. Sammie and I looked at it while we were camping in the area one weekend and I took her on a mystery trip. I said there is an Elite that we should take a look at. She's like ok, lets go see. After looking at it at the shop, she blew me away and said how cool it was and we should make an offer. I was taken aback but we made the guy an offer of $1800 and made arrangements to get it home. Like I said before... She's the BEST!

The engine was a disaster. Head was off, cams in boxes, parts everywhere. Disgusting interior with the classic droopy cloth headliner... I scratched my head for a long time on why I did this.
Well after settling in.... I went to work. After I proclaimed the existing engine a complete total loss, I went scouring the internet and found an engine in Dallas TX. Turns out the guy I bought it from had an Esprit he was working on for the "Flying Mile" Competition out west someplace. He new of a machine shop guy that was building him a twin turbo Buick V-8 that he was going to put into his Esprit for the flying mile. Unfortunately after that, the gentleman passed away, and his family contacted him to see if he wanted an engine that was under a work bench in the guys shop. Naturally he said yes. Turned out to be a 907 2.0 engine. He knew nothing about it or if it was even a running engine, just that it was a Lotus engine tucked under a workbench.
We struck a deal for $500 and I had it shipped home. I figured that how could I go wrong. Even if it didn't run the parts are worth that. Well Lo and behold, when I got it it had carbs, bell housing, clutch... a complete engine ready to install!

When it arrived, I was blown away how clean it was. The first thing I did was put oil down the cylinders and let it set. The next day I hooked up my compression tester to the cylinders, cranked it over by hand with a long Snapon ratchet and unbelievably, I got 70 psi out all jugs! With just a ratchet! I said this bastards gonna run!!!

Pulled out the old and in with the new.... Runs AWESOME!

Meanwhile, we tore out the interior once we were convinced that we had a runner here... and had that completely redone.

Check out the funky seats! Talk about '70's Style!!!

Before that we took out all the trim from the inside roof rails and the headliner... What a mess that was!! Shitty cloth and liner all over the place. Scraped and sanded the under side of the roof and glued new suede headliner in.

It was quite a project. The portions that look like 2 different colors is just because of the suede... brushing it to install. It actually looks beautiful when finished!

 

[78Brougham]

 

[saforwardlook]

That is an awesome story and a very rare automobile! I have never seen one, even in just a photo . Very amazing indeed to find a running replacement engine for it along with finding a wife like Sammie! Glad you are fixing up that Lotus.

 

[MarPar]

Jeezus H. How the hell did I miss this thread!?!?!

Top Notch work as always, Kenny my man. And yes, Sammie is THE best!

See, told ya to put the 7 up on the forum

 

[LocuMob]

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That is a labor of love, Lotus Gremlin!!! I'd love to hear Jeremy Clarkson's take on the car, I wonder what words he'd use to describe it's styling? What happened to the other two cars?

 

[MarPar]

That is a labor of love, Lotus Gremlin!!! I'd love to hear Jeremy Clarkson's take on the car, I wonder what words he'd use to describe it's styling? What happened to the other two cars?

No words...just this