Stone Chip Protection Film, Decals, Wheels, DVLA and Carbon Headlights

The car arrived back at CC midlands after being re-sprayed by XK Engineering last week.  Dean emailed me on Friday to say that the stone chip protection film and the decals were going to be fitted this week, with the remaining 'rebuild' of the car to commence after that.

Once again and sooner than expected I got an email from Dean this morning saying the stone chip protection film and decals had been applied.  He also supplied some pictures, and even from the pictures it looks like the paint is extremely shiny... Dean has suggested the paint has a deeper shine and apparently one of the mechanics commented how good the paint is, thinking it had a glass like finish.  I just hope the stone chip protection film will go some way to protecting this.

We decided it best to fit the stone chip protection film, then the decals on top of the film... The nose, rear wings, and full height sides of the car have been covered with the sides being covered as far forward as was possible.  So really the only areas that could get chipped are the bonnet, scuttle and behind the rear wheels.

Caterham R500 looking very shiny, now with stone chip protection film and new triple stripe decals.

Another full view of the R500

Offside view of Caterham R500 decals, now correctly aligned too! 

A view of the rear triple stripe

The wheels also came back from the power coating company today, and they too look like they have a real nice deep colour.

I think these are the front wheels...

So that makes these the rears!

To pass the time whilst I was waiting for the car to be IVA'd and the remedial works to be resolved, I managed to spend a few quid on some carbon headlights from a carbon manufacturer in Germany.... I went with the 2x2 weave, and they arrived last week... The laying of the weave and the construction was very good indeed, but... unfortunately they arrived scratched and looked as though no lacquer had been applied - I was not impressed, especially as they cost a hell of a lot of money.  

Caterham Carbon Headlight Bowls with highlighted scratches

I expressed my dissatisfaction at the quality of the finish to my contact there, and she agreed it was not up to their usual standard.  She then organised for the headlights to be collected, refinished, lacquered and I received confirmation from her today that they have now been re-shipped to me, so these should be with me on Monday... I'll do a post about the headlights, swapping them over with the existing headlights, and a weight comparison too!  I also have some other carbon light bits for the rear, namely indicator blocks and rear fog light and reversing light blocks - again I'll post about changing these over when I get the car back.

The DVLA have been spoken to today, and they believe the registration paperwork will be finished on Friday of this week (30th May 2014).  

So the next stage for Dean and the team at CC midlands, is to put the final bits of the car back together, fit the seats and harnesses and then tell me it's ready to collect!  All being well hopefully by mid to end of next week I'll FINALLY have my car back.  Happy days!  I just need to pray for some decent weather!

Back from the spray shop

Received the email from Dean today to say the car has been returned from XK engineering, the paint has been inspected and he says the paint work is awesome (I don't think that's meant to take anything away from the CC factory paint jobs, but to emphasise how good XK are at this sort of thing).  The car has been painted clear over base, which is different to the standard two pack paint (which is so susceptible to the chipping), having said that I understand that as it's an open wheeled car and so low to the ground stone chips are inevitable and add a certain amount of patina to the history of the car.  But I'm glad I've now got a clear coat over the top of my base colour (of Porsche Riveria Blue 39E) which will go some way to protecting the overall finish of the paint.

Here is a picture of the car as it was being unloaded off the XK Engineering flat bed lorry:-

My Caterham R500 on XK engineering flat bed lorry after re-painting.

To further protect the paint, I am having stone chip protection film fitted to the nose cone, the full length of the body panels and on the rear arches.  This is booked in for Wednesday next week (28th May 2014), and I expect the triple strip decals to be refitted then too.  In the meantime the wheels are off being powder coated, the car will be re-assembled, the 620R seats and harnesses will be fitted (when they arrive) and then it'll be time to collect.

The registration paperwork was sent off to the DVLA on the 6th or 7th of May, which would mean it's been with them for around two weeks now... I spoke to them (the DVLA) a few days ago and it transpires that as I already have a number plate - R500 WOT (WOT=wide open throttle) that provided I can prove the documentation was delivered to the DVLA by way of signed for recorded delivery from Royal Mail I'd actually have a 14 day grace period to use the vehicle WITHOUT the need for a V5 or tax disc, however, if the paperwork isn't back with me after the 14 day grace period expires I'd have to stop using the vehicle.  

The point I'm trying to make is that any future builders that don't want to wait to drive their cars once the IVA has been approved, should purchase a private plate in advance and then can use their cars as soon as they can prove the documentation has been received by the DVLA - amazing, but true!

The paintwork report

As a careful builder I was very meticulous with my handling of tools, being careful around the bodywork, masking things up and so on.  However, even being as careful as I was it seemed inevitable that during the build process I managed to chip / scuff my paint in a number of areas (without knowing) which in turn led me to believe there was an issue with the paint.  The paint (to me) seemed like it was too soft, or had not been hardened properly. 

I made a comprehensive (to say the least) document of bits and pieces that I wanted checking at PBC (post build check) stage and rectifying prior to me taking eventual receipt of the vehicle, and the paintwork was a fairly substantial part of this "dossier".

Dean (CC midlands) sent my bonnet off to http://www.xkengineering.com/ last week for testing.  XK engineering are not the original painters of the car, and as such today provided an independent report as to what the paint status is.  The great news for me (and reassuring for other potential Caterham owners) is the paint is in fact good.  The report states:

• First test 95% adhesion (just a few edges lifted) still a pass though.
• Second test 100% adhesion.
• There is nothing wrong with the paint adhesion/strength of the paint on the bonnet supplied.

So Dean and I have spoken about the paint test results this morning, and we've come to the conclusion that although the paint is good, rectifying some of the areas where the paint is chipped / scuffed will be extremely difficult. Also if these bits in question were just blended in, there is the probability that the finish will not be as good as if it were newly painted from the factory. So..... and quite drastically sounding - we've agreed to repaint the car!  The car will be disassembled today (where required) then sent off to XK engineering tomorrow.  The bodywork will be prepped accordingly, the car will be repainted and should be back with Dean at CC midlands early next week.

Some pictures below of the areas of paintwork that were in question:


Scratch on carbon nosecone - this was there out of the bubble wrap packaging

 

Chips where nosecone meets front of bodywork covering chassis

 

Scuffing where hood sticks attach to top of rear bulkhead

 

Scratch on drivers side carbon rear wing - no idea how this got there

 

Chip on passenger side entry arch - I've asked to get this armourfended as I can see this area getting some abuse

 

Removing the foam on the front scuttle actually lifted some of the paint off

 


Pretty sure this was chipped when the revised decals were fitted



XK engineering also offer a carbon tinting service - which looks very unique... Below is a picture of a red tinted front carbon cycle wing.  I think it could look really good on some cars, but this may just be a little bit too "bling" for me.



Red tinted carbon front cycle wing

Passing the time with videos, games and spending

With roughly two or three weeks until my car is ready for collection, I thought I'd share some things that have kept me in the 'Caterham' frame of mind...

In no particular order, here are some of the Caterham video's I've really been enjoying.

The very first start of my R500
As you'd expect I've probably contributed towards 90% of the views of this video...

R500 Top Gear Test Track Power Laptime
The top gear lap of the R500 has been great fun to watch, over and over and over again... It's great that the stig took the R500 round the top gear test track (on a cold day) four tenths of a second faster than a million quid Bugatti Veyron!  Amazing really, and here is a link to the full list of top gear test track power lap times.

Caterham R500 at Ledenon Circuit in France
Great onboard camera work by the passenger, exhaust note sounds great, good driving (spin at 4min 30 aside!) and an all together great R500 video.  The circuit looks really nice too, and totally suited to the R500.  Here's a link to the circuit - shame it's in the very south of France, as I'd quite like to go there to have a spin (not literally like this driver did!)

Caterham 620R at Anglesey Circuit
Some awesome drifting in this video, shame the camera position doesn't quite do the opposite lock angles justice...

Caterham R300 drifting

Some superb drift skills by Vincent Beltoise in this R300 running on slicks...

Caterham R500 Vs 996 GT2 - Nurburgring battle lap2

Probably the most viewed R500 video on YouTube, but rightly so - amazing driving and a great battle with a 996 GT2.

Real Racing 3

Real Racing 3 logo with Caterham 620R

I've spent quite a lot of time trying to unlock the Caterham 620R on real racing 3 on my iPad mini.  I've not actually unlocked it yet, but when I do you can be sure it'll have blue paint and orange stripes!  The game is actually really good - it's free for a start, you can race others online and it has a Caterham 620R in it - what more could you want!

Here is a link to the game on the Apple App Store:-

https://itunes.apple.com/gb/app/real-racing-3/id556164350?mt=8 

There is also an android version available on the Google Play Store, link here:-

https://play.google.com/store/apps/details?id=com.ea.games.r3_row

Spending - AKA "upgraditis"

I've already managed to spend some cash on a few carbon upgrades...!  2x2 weave carbon headlights, carbon rear light blocks, fog and reversing lights and a carbon handbrake lever too.  Not for anything other than the wow factor, but I'm sure there'll be a weight saving nonetheless.  I'll do a post of each item, with comparison weight savings, the change process along with some before and after pictures too.

Hopefully the DVLA will process my IVA paperwork promptly as I don't think I can sustain this level of spending in the vain attempt to keep my serotonin levels up!

And the paperwork's off

It's time to set my stopwatch - the countdown has begun... The reams and reams of paperwork have been completed by Dean and the team at CC Midlands, so it's now a only a matter of days until the car is ready for collection... According to the DVLA site it should take between 10 - 14 working days to process, however I'm aware of at least one individual who is now in week five of his wait!  Naturally (and like everyone) I hope mine will be sooner rather than later, but that's down to the DVLA and their processing "black hole" so who knows when I'll actually get the V5.

Dean sent me a picture of the vast number of written documents that need to be sent to the DVLA to get my V5 - and quite frankly I'm glad I didn't have to complete this lot.


The vast number of written documents that need to be sent to the DVLA to get a V5

The envelope of documents addressed to the DVLA.

Now that the paperwork is well and truly "in the post" it's now down to the final issues to be rectified.

The first item Dean has wanted to understand is the paintwork, so he has sent my bonnet to the paint shop that they use to have the paint tested for hardness and also how well it is adhering to the body.  It’ll be interesting to hear what the outcome is.  Maybe it is right, but during the build I got myself into such a frenzy that I was double and triple checking everything... Having said that there are some marks (top of nosecone) that were there when the bubble wrap came off, so I'm not convinced right now it is correct, BUT... We'll wait and see what the outcome is. 

It's a great feeling knowing that rectification issues are gradually being ticked off the list and I'm getting closer to that momentous collection day!

It passed the IVA - 2nd time!!

With the fuel pump fiasco well and truly behind us, the team at CC Midlands set out by fitting the fuel pump and starting my car (see previous post) then prepping it for the IVA.  According to Dean they (CC Midlands) have a really good working relationship with the Nottingham VOSA test centre, and they could get my car booked in at a couple of days notice.  No doubting required here, the fuel pump arrived on the 28th April, the car was started for the first time on the 29th April, and it was booked in at the VOSA test centre for the coming Friday!

So the car was readied for the test, loaded into a covered car transporter and taken up to Nottingham to be tested.


The R500 loaded into a covered car transporter ready to be taken to Nottingham VOSA test centre.

Side view of the car in the transporter (fitted with standard tillet seats)

Another view of the car in the transporter - note the bundles of spare IVA trim!

Unfortunately, I don't have any pictures of the car being tested as it's a VOSA test centre, and they don't allow it.

With the IVA booked for 8:30am on Friday 2nd May 2014 I decided it was a good idea to go for a few beers the night before (when isn't going for a few beers a good idea??).  I subsequently had a pretty manic day in the office, so it wasn't until lunchtime that I realised I hadn't had the "it's passed" call or email...  I spent the next hour or two nervously watching my iPhone and Outlook mailbox for a call or email.  Then... an email popped up from Dean Francis to say unfortunately it had failed.  I was a bit gutted, as I thought I would've heard something by now if it was good news... Anyway, there was still some good news - the team up at Midlands had swiftly devised a work around and re-booked the car for this morning (Tuesday 6th May 2014) so only a day lost.

Why did it fail...?  Noise, and noise alone.  The R500 has a short exhaust can so the work around was to fit a longer can with a larger diameter.

This obviously worked, as I've had the email and subsequent call to say all is now well and my car is now approved!  Superb news.  If I'm honest, I was climbing the walls at the weekend... A few friends were at the LOT (Lotus on Track) track day in Folembray, France (which I'd booked back in Nov-13 thinking I'd be there) alas it wasn't to be.  BUT... Dean has the certificate of newness and my certificate of entitlement, so I'm happy as I write this post.

My next jobs are to send a scanned copy of my driving licence, a copy of a utility bill and my insurance cover note to Dean so he can complete whatever paperwork is necessary and get the forms off to the DVLA.  Dean said that his 620R customers are getting good prices for insurance from Lloyd and Whyte so I gave them a call, and got a pretty good price including 5 track days, European trips, European tracks (Nurburgring aside) so agreed the price with Ryan at Lloyd and Whyte and he emailed the cover note to Dean this afternoon.

Prior to collection there is still work to be done from Caterhams front.  There was a reasonable list of remedial works I wanted rectifying prior to collection, but...  I'm not going to dwell on that now, as it's already been said, and based on my current experiences with Dean to date, he's not let me down.