Ep 4. Caterham Seven

The episode titled "Caterham Seven" in season 2 of How It's Made: Dream Cars takes viewers behind the scenes of the production of the iconic sports car. The Caterham Seven has been around for over 60 years and is known for its lightweight design and impressive performance capabilities.

The episode begins at the Caterham factory in England, where we are introduced to the team responsible for building the car. We learn that the process of building a Caterham Seven is a highly skilled and labor-intensive process. The car is made almost entirely by hand, with each component carefully crafted and assembled by skilled technicians.

The first step in the production process is to create the frame of the car. This is done using 25mm steel tubes that are bent and welded together to form the chassis. Once the frame is complete, the next step is to add the suspension, which is made up of aluminum wishbones and shock absorbers. This is a delicate process, as each component needs to be precisely aligned to ensure the car handles well on the road.

The next step in the production process is to add the engine and gearbox. The Caterham Seven is available with a range of engine options, including Ford and Cosworth units. These engines are carefully installed by hand, with each component checked and double-checked to ensure everything is working as it should be.

With the engine and gearbox in place, the team moves on to installing the brakes. The Caterham Seven uses disc brakes at the front and rear of the car, which are carefully calibrated to ensure optimum stopping power. The brake calipers are painted bright red, adding a splash of color to the car's sleek design.

The final step in the production process is to install the bodywork. The Caterham Seven is known for its minimalist design, with a lightweight body that is styled to minimize drag and maximize speed. The body panels are made from lightweight composite materials that offer excellent strength and durability while also keeping weight to a minimum.

Throughout the episode, we get a real sense of the care and attention that goes into building a Caterham Seven. Each car is made to order, with customers able to specify exactly the features they want. From the engine and transmission to the color of the bodywork, every detail of the car is customizable.

Overall, "Caterham Seven" is an excellent episode of How It's Made: Dream Cars that offers a fascinating insight into one of the world's most iconic sports cars. From the frame to the brakes, we see every step of the production process in detail, gaining a real appreciation for the level of craftsmanship that goes into building a Caterham Seven. If you're a car enthusiast or just curious about how things are made, this is an episode not to be missed.