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barry
 



Left hand side engine mount. Exhaust manifolds have been removed, so you can also see the alternator, oil filter and starter motor more easily.

As we removed the engine Mark mentioned that on his Superlight the left hand side engine mount had failed. On inspection I found that ours was also failing in the same way. A small crack was developing where the bracket is welded together at the point that fixes to the engine block, as can be seen in these pictures.

Cleaning the old paint and rust layer off revealed a small crack.


Hairline crack just visible.

This engine mount has since been redesigned and strengthened by Caterham - ours is an early version. As soon as I get a new mount I shall post a picture showing what the new one looks like.

 


We have also had our rear exhaust mounting strap break a few times. This fixing point comes under immense strain - it holds the weight of the silencer box and exhaust as the car bounces and twists along bumpy roads.

Strap has just snapped. This means that the only way the exhaust is fixed to the car is where it bolts to the engine. That leaves a large weight bouncing freely. 

It is pretty easy to replace - here I have used a thicker gauge of stainless steel, cut and drilled to the correct shape and size, using the old one as a guide. The only trouble you might have is with the bolt that goes into the chassis. Ours had obviously not moved for a few years, and the first time we had to remove it it sheared off, leaving the bolt in the chassis. I had to drill and re-tap the hole. Make sure you give the bolt a good soaking with release agent before you try and remove it, if it has been in there for any length of time.

Our temporary fix, as a 'get you home' it works well. A strap around the rubber exhaust mount which is still attached to the exhaust, up and around the roll bar. The cardboard is there to prevent the strap from rubbing the paintwork. Drive like this for too long and the strap is likely to melt.


Another busy day in Marks garage!


Floating Caterham and original Lotus 7 - and a leg or two!


Next lot of customers lining up for treatment!!




 
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