ASSESSOR SUMMER 2025 FULL MAGAZINE v2 - Flipbook - Page 33
Gary Hunt, whose efforts in
securing funding allowed the visit
to be a complimentary event for all
participants.
CRAFTSMANSHIP AT THE CORE
What sets Caterham apart is its
commitment to hand-built excellence.
Each car is assembled by a single
technician, whose name is proudly
af昀椀xed to the 昀椀nished vehicle. A
basic model takes approximately two
weeks to complete, while higher-spec
variants can require up to four weeks.
This approach ensures consistency,
accountability, and a personal touch
that mass production simply cannot
replicate.
Trainees typically spend a year
mastering the assembly of base models
before progressing to more complex
builds. This structured development
pathway not only safeguards quality
but also nurtures a deep understanding
of the vehicle’s engineering.
ENGINEERING INSIGHTS
Caterham’s engineering is as thoughtful
as it is thrilling. The chassis, composed
of two main sections – the basket and
the long front, can be repaired with
precision using factory jigs, allowing
damaged sections to be replaced
without compromising alignment.
The engine room is climate-controlled
to maintain consistent torque settings
during assembly. Models such as the
360 and 420 feature upgraded pistons
with modi昀椀ed crowns, while the 485
and 480 bene昀椀t from a Japanese roller
barrel inlet manifold setup. Dry sump
options are available on select models
to optimise weight distribution.
Caterham is also adapting to
changing powertrain landscapes. Ford
hybrid engines are currently being
modi昀椀ed back to internal combustion
con昀椀gurations to suit Caterham’s
performance goals. Though the Ford
Duratec engine will soon be phased
out in favour of the Horse unit, a new
4 cylinder turbocharged 1.3 litre.
Lightweight and with plenty of scope
for tuning, an exciting time for
Caterham.
A BALANCE OF TRADITION
AND INNOVATION
Despite the availability of factory-built
cars, Caterham continues to honour
ts roots by offering kits for
self-assembly, a nod to Chapman’s
original vision of owner-built
performance. The Westbury division
fabricates the chassis and hand-forms
body panels, with each side panel
requiring around eight hours of
preparation. Shells are delivered
weekly, supporting an annual
production capacity of 750 units,
currently on the rise from 500 thanks
to Caterham’s increased production
capability in the new factory.
www.iaea-online.org/news/the-assessor | SUMMER 2025 | THE ASSESSORS JOURNAL
Two dedicated paint booths ensure
a 昀氀awless 昀椀nish, using PPG paints to
achieve a wide range of high-quality
昀椀nishes, from solid colours to complex
three-and four-stage pearls. This
allows Caterham to offer both classic
and contemporary aesthetics while
maintaining the brand’s commitment to
craftsmanship and visual appeal.
CONCLUSION
Caterham Cars is more than a
manufacturer; it is a custodian of a
driving philosophy that prioritises
connection, simplicity, and joy. For
automotive engineers and assessors,
the Dartford facility offers a masterclass
in how tradition and innovation can
coexist without compromise. In an
era of increasing automation and
digitalisation, Caterham’s approach is
a refreshing reminder of the power of
human craftsmanship and mechanical
purity.
JOURNAL
Author: Peter Beddow A.Inst.AEA MFIEA CAE
MIMI EngTech MIMechE
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