A few bits and bobs were removed, and having changed to an aero screen (with no intentions of ever putting the screen back on) I thought that the next quick and easy weight saving would be to remove the hood sticks and replace the boot cover.
I ordered the new boot cover towards the back end of last year, but as the car hasn't been with me for the last couple of months I couldn't remove the hood sticks and fit the new cover, so as part of my 2016 prep here is the removal and new boot cover refitting guide.
Now onto the Hood stick removal and boot cover refitting guide.
This guide is just the way I found it worked best, and I'd suggest reading the whole post before committing yourself.
Firstly undo all of the poppers on the boot cover and velcro around the top of the roll bar as per the picture below which should give you good access to the hood sticks and inside of the boot.
|Getting access to the hood sticks|
Removing the hood sticks is actually very straight forward. Literally undo these bolts on both sides, and unscrew the two self tapping screws holding the nylon fabric strips into the inside boot lip and the hood sticks are free!
|Removing hood sticks is only a matter of undoing two bolts and two self tapping screws|
|Caterham hood sticks weighed in at 1.5kg|
|Remove the harness bolts and self tapping poppers.|
|The boot cover (for cars with hood sticks) weighed in at 832g|
|Removing the metal strip from the passenger side of the boot cover|
|Caterham boot cover (no hood sticks) weighed in at 578g (inc fasteners)|
|Leading edge of rear boot cover marked up ready for holes to be cut|
|Using punch tool to cut holes into the boot cover|
|Front of boot cover fitted|
|Rear of boot cover marked ready for hole punching and poppers to be fitted|
With all the holes punched, and no doubt a sore hand again! You'll need to get the dot fastener tool out. Put the fastener in the rounded part of the tool, and the socket in the top part (as pictured below) then the metal into the brass section of the fastener then using a metal hammer a couple of light to medium taps and it'll be all secure. Repeat for all poppers.
|Fitting the poppers to the boot cover using the dot fastener tool|
|Caterham R500 with new boot cover (without hood sticks)|