Time spent: 5h
Cumulative time: 71h
Main activities:  rear wings, intercooler, rear axle

Miserable cold weather today with snow flurries.  So I tried to do as much as I could indoors.

The rear axle was a relatively easy job (but slightly messy because of the silicone gasket material).  After several checks to make sure I have it the right way round – the diff is not symmetrical which helps work out the orientation compared with the image in the Assembly Guide – I fitted the diff into the housing.  The bolts had thread lock on them and torqued up fine.

The little breather vent cover on the top (with its small rubber washer and spring) required a couple of firm taps with the rubber mallet to go into place.

I have left it indoors having wiped off the excess mastic whilst I wait for warmer times to put it onto the car. Caterham advised using a high temperature sealant for this. [only a small amount was needed so I was able to sell on the remainder along with some of the other partially-used consumables]

A pack from Caterham arrived this morning with the correct bobbins for the air cooler so I fitted that into place and added the respective hoses.  I seem to have an enormous number of jubilee clips but none were a close match for the air hoses to and from the intercooler.

So I ended up using one of the large ones and then screwing them almost to the extent it would go.  Apart from the issue of getting at the jubilee clip for the connection on the underside of the intercooler (used a socket on an extension bar in the end), it was not troublesome to fix this all.

The other jobs involved fitting the lights to the wings.  Pretty self-explanatory (but one of those annoying ones with imperial fixings). There are some long hollow fixings that go onto the bolts coming out of the lights. Some wedges are included to give a flat surface to allow the fixing to be tightened against the curve of the wing. I also needed to include two flat washers to allow the fixing to get tight.

The hole in the rear  wing for the light connection looks like a perfect grot trap.  I have patched it with some of the stick-on foam I have got to line the inside of the wings and we will see how it lasts.  Still trying to think of a better solution for this.